Systems and methods for additively manufacturing composite parts

ABSTRACT

A method ( 300 ) of additively manufacturing a composite part ( 102 ) is disclosed. The method ( 300 ) comprises depositing a segment ( 120 ) of a continuous flexible line ( 106 ) along a print path ( 122 ). The continuous flexible line ( 106 ) comprises a non-resin component ( 108 ) and a thermosetting resin component ( 110 ) that is not fully cured. The method ( 300 ) further comprises, while advancing the continuous flexible line ( 106 ) toward the print path ( 122 ), delivering a predetermined or actively determined amount of curing energy ( 118 ) at least to a portion ( 124 ) of the segment ( 120 ) of the continuous flexible line ( 106 ) at a controlled rate after the segment ( 120 ) of the continuous flexible line ( 106 ) is deposited along the print path ( 122 ) to at least partially cure at least the portion ( 124 ) of the segment ( 120 ) of the continuous flexible line ( 106 ).

RELATED APPLICATION

This application claims priority to U.S. Provisional Patent ApplicationNo. 62/199,665, entitled “SYSTEMS AND METHODS FOR ADDITIVELYMANUFACTURING COMPOSITE PARTS,” which was filed on Jul. 31, 2015, andthe complete disclosure of which is hereby incorporated by reference.

BACKGROUND

Conventionally, manufacturing of typical composite parts relies onsequential layering of multiple plies of composite material, with eachply containing, e.g., unidirectional reinforcement fibers or randomlyoriented chopped fibers. Parts manufactured in this manner must havelaminar construction, which undesirably increases the weight of thefinished part, since not all of the reinforcement fibers are orientedalong the direction(s) of the force(s) to be applied to the parts.Additionally, limitations inherent to laminar techniques ofmanufacturing composites are not conducive to implementation of manytypes of advanced structural designs.

SUMMARY

Accordingly, apparatuses and methods, intended to address at least theabove-identified concerns, would find utility.

The following is a non-exhaustive list of examples, which may or may notbe claimed, of the subject matter according the present disclosure.

One example of the present disclosure relates to a system for additivelymanufacturing a composite part. The system comprises a delivery guide,movable relative to a surface. The delivery guide is configured todeposit at least a segment of a continuous flexible line along a printpath. The continuous flexible line comprises a non-resin component and athermosetting resin component. The thermosetting resin componentcomprises a first part of a thermosetting resin and a second part of thethermosetting resin. The print path is stationary relative to thesurface. The delivery guide comprises a first inlet, configured toreceive the non-resin component, and a second inlet, configured toreceive at least the first part of the thermosetting resin. The deliveryguide is further configured to apply the first part of the thermosettingresin and the second part of the thermosetting resin to the non-resincomponent. The system further comprises a feed mechanism, configured topush the continuous flexible line out of the delivery guide.

Another example of the present disclosure relates to a method ofadditively manufacturing a composite part. The method comprisesdepositing a segment of a continuous flexible line along a print path.The continuous flexible line comprises a non-resin component and athermosetting resin component that is not fully cured. The methodfurther comprises, while advancing the continuous flexible line towardthe print path, delivering a predetermined or actively determined amountof curing energy at least to a portion of the segment of the continuousflexible line at a controlled rate after the segment of the continuousflexible line is deposited along the print path to at least partiallycure at least the portion of the segment of the continuous flexibleline.

Yet another example of the present disclosure relates to a method ofadditively manufacturing a composite part. The method comprises applyinga thermosetting resin to a non-resin component of a continuous flexibleline while pushing the non-resin component through a delivery guide andpushing the continuous flexible line out of the delivery guide. Thecontinuous flexible line further comprises a thermosetting resincomponent that comprises at least some of the thermosetting resinapplied to the non-resin component. The method further comprisesdepositing, via the delivery guide, a segment of the continuous flexibleline along a print path.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described examples of the present disclosure in generalterms, reference will now be made to the accompanying drawings, whichare not necessarily drawn to scale, and wherein like referencecharacters designate the same or similar parts throughout the severalviews, and wherein:

FIG. 1 is a schematic diagram of a system for additively manufacturing acomposite part, according to one or more examples of the presentdisclosure;

FIG. 2 is a schematic cross-sectional view of a delivery guide of thesystem of FIG. 1, according to one or more examples of the presentdisclosure;

FIG. 3 is a schematic cross-sectional view of a delivery guide of thesystem of FIG. 1, according to one or more examples of the presentdisclosure;

FIG. 4 is a schematic illustration of a feed assembly and a deliveryguide of the system of FIG. 1, according to one or more examples of thepresent disclosure;

FIG. 5 is a schematic illustration of a feed assembly and a deliveryguide of the system of FIG. 1, according to one or more examples of thepresent disclosure;

FIG. 6 is a schematic cross-sectional view of a continuous flexible linedeposited by the system of FIG. 1, according to one or more examples ofthe present disclosure;

FIG. 7 is schematic cross-sectional view of a continuous flexible linedeposited by the system of FIG. 1, according to one or more examples ofthe present disclosure;

FIG. 8 is a schematic view of a portion of the system of FIG. 1,illustrating two layers of continuous flexible line being curedsimultaneously, according to one or more examples of the presentdisclosure;

FIG. 9 is a schematic illustration of a portion of the system of FIG. 1,in which a delivery guide comprises a curing-energy passage, accordingto one or more examples of the present disclosure;

FIG. 10 is a schematic illustration of a portion of the system of FIG.1, in which a delivery guide comprises a curing-energy passage andcuring energy is delivered in the form of a ring, according to one ormore examples of the present disclosure;

FIG. 11 is a schematic illustration of a portion of the system of FIG.1, in which curing energy is delivered in the form of a ring, accordingto one or more examples of the present disclosure;

FIG. 12 is a schematic illustration of a delivery guide and a compactor,comprising a compaction roller of the system of FIG. 1, according to oneor more examples of the present disclosure;

FIG. 13 is a schematic illustration of a portion of the system of FIG. 1with a compactor comprising a compaction roller, according to one ormore examples of the present disclosure;

FIG. 14 is a schematic illustration of a portion of the system of FIG. 1with a compactor comprising a compaction roller, according to one ormore examples of the present disclosure;

FIG. 15 is a schematic illustration of a portion of the system of FIG. 1with a compactor comprising a compaction wiper, according to one or moreexamples of the present disclosure;

FIG. 16 is a schematic illustration of a portion of the system of FIG. 1with a compactor comprising a skirt, according to one or more examplesof the present disclosure;

FIG. 17 is a schematic illustration of a cutter comprising aniris-diaphragm of the system of FIG. 1, according to one or moreexamples of the present disclosure;

FIG. 18 is a schematic illustration of a portion of the system of FIG. 1with a cutter comprising two blades movable relative to a deliveryguide, according to one or more examples of the present disclosure;

FIG. 19 is a schematic illustration of a portion of the system of FIG. 1with a cutter comprising at least one blade positioned within a deliveryguide, according to one or more examples of the present disclosure;

FIG. 20 is a schematic illustration of the system of FIG. 1 with acutter comprising a cutting laser, according to one or more examples ofthe present disclosure;

FIG. 21 is a schematic illustration of the system of FIG. 1 with asource of curing energy comprising one or more curing lasers, accordingto one or more examples of the present disclosure;

FIG. 22 is a view of the system of FIG. 1 comprising a frame and a driveassembly, according to one or more examples of the present disclosure;

FIG. 23 is a view of a portion of the system of FIG. 1 with a cutter, acompactor, a surface roughener, and a curing source comprising a curinglaser, according to one or more examples of the present disclosure;

FIG. 24 is a view of a portion of the system of FIG. 1 with a curingsource comprising a curing laser, according to one or more examples ofthe present disclosure;

FIG. 25 is a view of a portion of the system of FIG. 1 with a compactorand a curing source comprising a curing laser, according to one or moreexamples of the present disclosure;

FIG. 26 is a view of a portion of the system of FIG. 1 with a curingsource comprising a curing laser, according to one or more examples ofthe present disclosure;

FIG. 27 is a view of a portion of the system of FIG. 1 with a curingsource comprising two curing lasers, according to one or more examplesof the present disclosure;

FIG. 28 is a view of a portion of the system of FIG. 1 with a curingsource comprising four curing lasers, according to one or more examplesof the present disclosure;

FIG. 29 is a view of a portion of the system of FIG. 1 illustrating afeed mechanism, according to one or more examples of the presentdisclosure;

FIG. 30 is another view of the portion of FIG. 29;

FIG. 31 is another view of the portion of FIG. 29;

FIG. 32 is a view of a portion of the system of FIG. 1 with a cuttercomprising two blades movable relative to a delivery guide, according toone or more examples of the present disclosure;

FIG. 33 is another view of the portion of FIG. 32;

FIGS. 34A, 34B, 34C, and 34D collectively are a block diagram of amethod for additively manufacturing composite parts, according to one ormore examples of the present disclosure;

FIGS. 35A, 35B, 35C, and 35D collectively are a block diagram of amethod for additively manufacturing composite parts, according to one ormore examples of the present disclosure;

FIG. 36 is a block diagram representing aircraft production and servicemethodologies;

FIG. 37 is a schematic illustration of an aircraft; and

FIG. 38 is a schematic illustration of the system of FIG. 1, in whichtwelve degrees of freedom are provided between a delivery guide and asurface, according to one or more examples of the present disclosure.

DETAILED DESCRIPTION

In FIG. 1, referred to above, solid lines, if any, connecting variouselements and/or components may represent mechanical, electrical, fluid,optical, electromagnetic and other couplings and/or combinationsthereof. As used herein, “coupled” means associated directly as well asindirectly. For example, a member A may be directly associated with amember B, or may be indirectly associated therewith, e.g., via anothermember C. It will be understood that not all relationships among thevarious disclosed elements are necessarily represented. Accordingly,couplings other than those depicted in the schematic diagram also mayexist. Dashed lines, if any, connecting blocks designating the variouselements and/or components represent couplings similar in function andpurpose to those represented by solid lines; however, couplingsrepresented by the dashed lines either may be selectively provided ormay relate to alternative examples of the present disclosure. Likewise,elements and/or components, if any, represented with dashed lines,indicate alternative examples of the present disclosure. One or moreelements shown in solid and/or dashed lines may be omitted from aparticular example without departing from the scope of the presentdisclosure. Environmental elements, if any, are represented with dottedlines. Virtual imaginary elements also may be shown for clarity. Thoseskilled in the art will appreciate that some of the features illustratedin FIG. 1 may be combined in various ways without the need to includeother features described in FIG. 1, other drawing figures, and/or theaccompanying disclosure, even though such combination or combinationsare not explicitly illustrated herein. Similarly, additional featuresnot limited to the examples presented, may be combined with some or allof the features shown and described herein.

In FIGS. 34-36, referred to above, the blocks may represent operationsand/or portions thereof and lines connecting the various blocks do notimply any particular order or dependency of the operations or portionsthereof. Blocks represented by dashed lines indicate alternativeoperations and/or portions thereof. Dashed lines, if any, connecting thevarious blocks represent alternative dependencies of the operations orportions thereof. It will be understood that not all dependencies amongthe various disclosed operations are necessarily represented. FIGS.34-36 and the accompanying disclosure describing the operations of themethod(s) set forth herein should not be interpreted as necessarilydetermining a sequence in which the operations are to be performed.Rather, although one illustrative order is indicated, it is to beunderstood that the sequence of the operations may be modified whenappropriate. Accordingly, certain operations may be performed in adifferent order or simultaneously. Additionally, those skilled in theart will appreciate that not all operations described need be performed.

In the following description, numerous specific details are set forth toprovide a thorough understanding of the disclosed concepts, which may bepracticed without some or all of these particulars. In other instances,details of known devices and/or processes have been omitted to avoidunnecessarily obscuring the disclosure. While some concepts will bedescribed in conjunction with specific examples, it will be understoodthat these examples are not intended to be limiting.

Unless otherwise indicated, the terms “first,” “second,” etc. are usedherein merely as labels, and are not intended to impose ordinal,positional, or hierarchical requirements on the items to which theseterms refer. Moreover, reference to, e.g., a “second” item does notrequire or preclude the existence of, e.g., a “first” or lower-numbereditem, and/or, e.g., a “third” or higher-numbered item.

Reference herein to “one example” means that one or more feature,structure, or characteristic described in connection with the example isincluded in at least one implementation. The phrase “one example” invarious places in the specification may or may not be referring to thesame example.

As used herein, a system, apparatus, structure, article, element, orcomponent “configured to” perform a specified function is indeed capableof performing the specified function without any alteration, rather thanmerely having potential to perform the specified function after furthermodification. In other words, the system, apparatus, structure, article,element, or component is specifically selected, created, implemented,utilized, programmed, and/or designed for the purpose of performing thespecified function. As used herein, “configured to” denotes existingcharacteristics of a system, apparatus, structure, article, element, orcomponent which enable the system, apparatus, structure, article,element, or component to actually perform the specified function. Forpurposes of this disclosure, a system, apparatus, structure, article,element, or component described as being “configured to” perform aparticular function may additionally or alternatively be described asbeing “adapted to” and/or as being “operative to” perform that function.

Illustrative, non-exhaustive examples, which may or may not be claimed,of the subject matter according the present disclosure are providedbelow.

Referring, e.g., to FIG. 1, system 100 for additively manufacturingcomposite part 102 is disclosed. System 100 comprises delivery guide112, movable relative to surface 114. Delivery guide 112 is configuredto deposit at least segment 120 of continuous flexible line 106 alongprint path 122. Continuous flexible line 106 comprises non-resincomponent 108 and thermosetting resin component 110. Thermosetting resincomponent 110 comprises first part 253 of thermosetting resin 252 andsecond part 255 of thermosetting resin 252. Print path 122 is stationaryrelative to surface 114. Delivery guide 112 comprises first inlet 170,configured to receive non-resin component 108, and second inlet 250,configured to receive at least first part 253 of thermosetting resin252. Delivery guide 112 is further configured to apply first part 253 ofthermosetting resin 252 and second part 255 of thermosetting resin 252to non-resin component 108. System 100 further comprises feed mechanism104, configured to push continuous flexible line 106 out of deliveryguide 112. The preceding subject matter of this paragraph characterizesexample 1 of the present disclosure.

System 100 therefore may be used to manufacture composite parts 102 fromat least a composite material that is created from thermosetting resin252 and non-resin component 108 while composite part 102 is beingmanufactured. In addition, system 100 may be used to manufacturecomposite parts 102 with continuous flexible line 106 being oriented indesired and/or predetermined orientations throughout composite part 102,such as to define desired properties of composite part 102.

Because continuous flexible line 106 is created by system 100 indelivery guide 112 during manufacturing of composite part 102, system100 has the flexibility of permitting selection of different non-resincomponents 108 and/or different thermosetting resins 252 to customize orotherwise create a desired composite part 102 with differentcharacteristics at different locations within composite part 102.Moreover, because thermosetting resin 252 is applied to non-resincomponent 108 within delivery guide 112, which is downstream of feedmechanism 104, feed mechanism 104 may engage and operate directly onnon-resin component 108 without thermosetting resin 252 in liquid formhindering operation of feed mechanism 104. Additionally oralternatively, such a configuration may permit for greater control ofthe creation of thermosetting resin component 110, such as by avoidingthermosetting resin 252 in liquid form being withdrawn from non-resincomponent 108 by feed mechanism 104.

Some examples of system 100 additionally or alternatively may bedescribed as 3-D printers.

As mentioned, feed mechanism 104 is configured to push continuousflexible line 106 out of delivery guide 112. In other words, deliveryguide 112, which deposits continuous flexible line 106 along print path122, is positioned downstream of feed mechanism 104 with respect to adirection of movement of continuous flexible line 106 when compositepart 102 is being manufactured by system 100.

As used herein, the terms “upstream” and “downstream” relate to theintended direction of travel of non-resin component 108, thermosettingresin component 110, or thermosetting resin 252 generally through system100, or portion thereof, including, for example, feed mechanism 104 anddelivery guide 112.

As used herein, a “continuous flexible line” is an elongate structurehaving a length significantly longer than a dimension (e.g., diameter orwidth) that is transverse, or perpendicular, to its length. As anillustrative, non-exclusive example, continuous flexible line 106 mayhave a length that is at least 100, at least 1000, at least 10000, atleast 100000, or at least 1000000 times greater than its diameter orwidth.

As used herein, a “thermosetting resin” is a resin material that isconfigured to be cured, or hardened, by selective application of heatand/or radiation, and/or by time above a threshold curing temperature.Moreover, thermosetting resin 252 is comprised of first part 253 andsecond part 255. In some examples, thermosetting resin 252 may be anepoxy resin. In some examples, first part 253 and second part 255 may bedescribed as co-reactants. In some examples, such co-reactants may behardeners or curatives.

As mentioned, delivery guide 112 is movable relative to surface 114.This means that in some examples, system 100 may include delivery guide112 configured to be selectively moved relative to surface 114, whichsurface 114 may be a part of system 100 or a part of a structure, suchas an airplane wing or a fuselage, etc. Additionally, in examples wheresystem 100 includes surface 114, surface 114 may be selectively movedrelative to delivery guide 112. Also, in some examples, system 100 mayinclude delivery guide 112 and surface 114, and both may be selectivelymoved relative to each other.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 2, 3, and5, delivery guide 112 further comprises third inlet 257, configured toreceive second part 255 of thermosetting resin 252. The precedingsubject matter of this paragraph characterizes example 2 of the presentdisclosure, wherein example 2 also includes the subject matter accordingto example 1, above.

Accordingly, first part 253 and second part 255 of thermosetting resin252 are brought together within delivery guide 112 where thermosettingresin 252 is applied to non-resin component 108. Thus, the componentparts of thermosetting resin 252, that is, first part 253 and secondpart 255, may be maintained separately and brought together only whenbeing applied to non-resin component 108. As a result, thermosettingresin 252 does not begin to cure prior to being applied to non-resincomponent 108, and, depending on thermosetting resin 252 selected for aspecific application, only begins to cure just prior in time to beingdeposited by delivery guide 112 along print path 122.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 2 and 3,delivery guide 112 further comprises internal mixing structure 259,configured to operatively combine first part 253 and second part 255 ofthermosetting resin 252 within delivery guide 112. The preceding subjectmatter of this paragraph characterizes example 3 of the presentdisclosure, wherein example 3 also includes the subject matter accordingto example 2, above.

Internal mixing structure 259, when present, facilitates the mixing offirst part 253 and second part 255 of thermosetting resin 252, such asto ensure a uniform distribution of the component parts of thermosettingresin 252 and uniform property characteristics of thermosetting resincomponent 110, and thus of continuous flexible line 106.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 2 and 3,delivery guide 112 further comprises outlet 206 and line passage 154,extending from first inlet 170 to outlet 206. Outlet 206 is configuredto provide an exit for continuous flexible line 106 from delivery guide112. Internal mixing structure 259 comprises one or more mixing guides261, positioned within delivery guide 112, and configured to intermixfirst part 253 and second part 255 of thermosetting resin 252. Thepreceding subject matter of this paragraph characterizes example 4 ofthe present disclosure, wherein example 4 also includes the subjectmatter according to example 3, above.

Mixing guides 261, when present, facilitate mixing of first part 253 andsecond part 255 of thermosetting resin 252. Mixing guides 261 may takeany suitable form, such as to impart turbulent flow and/or change ofdirections of first part 253 and/or second part 255 to ensure adequatemixing thereof.

In some examples, mixing guides 261 may be described as baffles, vanes,and/or fins.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 2 and 3,one or more mixing guides 261 are at least partially discontinuous alongline passage 154. The preceding subject matter of this paragraphcharacterizes example 5 of the present disclosure, wherein example 5also includes the subject matter according to example 4, above.

By being discontinuous, mixing guides 261 may facilitate adequate mixingof first part 253 and second part 255 of thermosetting resin 252 withindelivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 2, only aportion of one or more mixing guides 261 defines line passage 154. Thepreceding subject matter of this paragraph characterizes example 6 ofthe present disclosure, wherein example 6 also includes the subjectmatter according to any one of examples 4 or 5, above.

By having a portion of one or more mixing guides 261, itself, defineline passage 154, through which non-resin component 108 is pushed byfeed mechanism 104, adequate coating and/or saturation of non-resincomponent 108 with thermosetting resin 252 may be achieved.

In FIG. 2, five differently configured mixing guides 261 are illustratedas examples only and do not limit the present disclosure to suchstructural mixing guides 261. Rather, as illustrative, non-exclusiveexamples only, mixing guides 261 may include a ramped construction, afunneled construction, a spiral construction, and/or a plate-likeconstruction. Additionally or alternatively, as illustrated in FIG. 2,line passage 154, as defined by mixing guides 161 may vary in widthand/or diameter among different mixing guides 161. Other configurationsof mixing guides 161 are within the scope of the present disclosure andthe examples illustrated in FIG. 2 are not limiting.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 2, atleast a portion of one or more mixing guides 261 is angled toward outlet206. The preceding subject matter of this paragraph characterizesexample 7 of the present disclosure, wherein example 7 also includes thesubject matter according to any one of examples 4-6, above.

By being angled toward outlet 206, mixing guides 261 may facilitate theinitial threading or feeding of non-resin component 108 through deliveryguide 112, as well as facilitate the feeding of non-resin component 108and continuous flexible line 106 through delivery guide 112 duringmanufacture of composite part 102.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 2, atleast the portion of one or more mixing guides 261 is angled towardoutlet 206 at a pitch that varies along line passage 154. The precedingsubject matter of this paragraph characterizes example 8 of the presentdisclosure, wherein example 8 also includes the subject matter accordingto example 7, above.

By having a varied pitch of mixing guides 261, radially inward regionsof mixing guides 261 may facilitate feeding of non-resin component 108and continuous flexible line 106 through delivery guide 112, whileradially outward regions of mixing guides 261, or mixing guides 261 as awhole, may facilitate mixing of first part 253 and second part 255 ofthermosetting resin 252. In some examples, a first mixing guide 261 mayhave a different pitch angle than the remaining mixing guides 261, withthe first mixing guide 261 being upstream of the other mixing guides261. In other examples, the pitch angle of the mixing guides 261 may notvary.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 2 and 3,delivery guide 112 has central longitudinal axis 270. Line passage 154is concentric with central longitudinal axis 270 of delivery guide 112.The preceding subject matter of this paragraph characterizes example 9of the present disclosure, wherein example 9 also includes the subjectmatter according to any one of examples 4-8, above.

Such a configuration of delivery guide 112 may facilitate sufficientapplication of thermosetting resin 252 to non-resin component 108, suchas coming into contact with an entire circumference of non-resincomponent 108 as it travels through delivery guide 112. Moreover, such aconfiguration may result in an efficient packaging of delivery guide112.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 3,delivery guide 112 further comprises outlet 206 and line passage 154,extending from first inlet 170 to adjacent outlet 206. Outlet 206 isconfigured to provide an exit for continuous flexible line 106 fromdelivery guide 112. Delivery guide 112 further comprises resin passage264, extending from second inlet 250 and third inlet 257 to adjacentoutlet 206. Internal mixing structure 259 comprises one or more mixingguides 261, positioned within resin passage 264. The preceding subjectmatter of this paragraph characterizes example 10 of the presentdisclosure, wherein example 10 also includes the subject matteraccording to example 3, above.

By having resin passage 264 separate from line passage 154 and havingmixing guides 261 of resin passage 264, adequate mixing of first part253 and second part 255 of thermosetting resin 252 may result prior tothermosetting resin 252 being applied to non-resin component 108. As aresult, pockets or concentrations of first part 253 and/or second part255 being absorbed by or adhering to non-resin component 108 may beavoided.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 3, linepassage 154 is isolated from resin passage 264 longitudinally along atleast a portion of line passage 154. Line passage 154 and resin passage264 are in fluid communication with each other adjacent to outlet 206,such that thermosetting resin 252 is applied to non-resin component 108adjacent to outlet 206. The preceding subject matter of this paragraphcharacterizes example 11 of the present disclosure, wherein example 11also includes the subject matter according to example 10, above.

Again, by having resin passage 264 separate from, and in this exampleisolated from, line passage 154, adequate mixing of first part 253 andsecond part 255 of thermosetting resin 252 may result prior tothermosetting resin 252 being applied to non-resin component 108.Moreover, by applying thermosetting resin 252 to non-resin component 108adjacent to outlet 206, feeding of non-resin component 108 through linepassage 154 may be more easily facilitated, in so far as non-resincomponent 108 is not wet with thermosetting resin 252 while being fedthrough line passage 154.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 3, one ormore mixing guides 261 are at least partially discontinuous along resinpassage 264. The preceding subject matter of this paragraphcharacterizes example 12 of the present disclosure, wherein example 12also includes the subject matter according to any one of examples 10 or11, above.

By being discontinuous, mixing guides 261 may facilitate adequate mixingof first part 253 and second part 255 of thermosetting resin 252 withinresin passage 264.

Referring to FIG. 1, delivery guide 112 is configured to provideselective access to internal mixing structure 259 for removing curedthermosetting resin 252 from delivery guide 112. The preceding subjectmatter of this paragraph characterizes example 13 of the presentdisclosure, wherein example 13 also includes the subject matteraccording to any one of examples 3-12, above.

Depending on a selected thermosetting resin 252, over time,thermosetting resin 252 may harden, or otherwise clog, delivery guide112, as a result of becoming cured, or partially cured. Accordingly, bybeing configured to provide selective access to internal mixingstructure 259, any cured thermosetting resin 252 may be able to beremoved for subsequent use of delivery guide 112 and system 100.

Referring to FIG. 1, delivery guide 112 further comprises first portion266 and second portion 268, configured to be selectively spaced awayfrom first portion 266. The preceding subject matter of this paragraphcharacterizes example 14 of the present disclosure, wherein example 14also includes the subject matter according to example 13, above.

By having two portions that may be selectively separated, at leastpartially, access to the internal volume and internal mixing structure259 may be permitted, such as to remove cured thermosetting resin 252.

Referring to FIG. 1, first portion 266 is hinged to second portion 268.The preceding subject matter of this paragraph characterizes example 15of the present disclosure, wherein example 15 also includes the subjectmatter according to example 14, above.

A hinged connection between first portion 266 and second portion 268 mayfacilitate and/or ease selective opening and closing of delivery guide112 for access to internal mixing structure 259.

Referring to FIG. 1, system 100 further comprises first vessel 262,configured to dispense first part 253 of thermosetting resin 252 tosecond inlet 250 of delivery guide 112. System 100 further comprisessecond vessel 272, configured to dispense second part 255 ofthermosetting resin 252 to third inlet 257 of delivery guide 112. Thepreceding subject matter of this paragraph characterizes example 16 ofthe present disclosure, wherein example 16 also includes the subjectmatter according to any one of examples 2-15, above.

Vessel 262 provides a volume of first part 253 of thermosetting resin252, and vessel 272 provides a volume of second part 255 ofthermosetting resin 252. Moreover, vessel 262 and vessel 272 may bereplenished during manufacture of composite part 102 and optionally maybe replenished with different first parts 253 and second parts 255,respectively, during manufacture of composite part 102, such as tocreate desired properties at different locations within composite part102.

Additionally or alternatively, more than one vessel 262 and/or more thanone vessel 272 may be provided, with individual vessels 262 and/orindividual vessels 272, each holding different first parts 253 and/ordifferent second parts 255, respectively, for selective delivery tosecond inlet 250 and third inlet 257, respectively.

Referring to FIG. 1, system 100 further comprises resin-metering system256, configured to actively control a flow of first part 253 ofthermosetting resin 252 to second inlet 250 of delivery guide 112 and toactively control a flow of second part 255 of thermosetting resin 252 tothird inlet 257 of delivery guide 112. The preceding subject matter ofthis paragraph characterizes example 17 of the present disclosure,wherein example 17 also includes the subject matter according to example16, above.

By actively controlling a flow of first part 253 and second part 255 todelivery guide 112, a desired volume of thermosetting resin 252 may bedelivered to delivery guide 112 and applied to non-resin component 108.Moreover, over supplying thermosetting resin 252 to delivery guide 112may be avoided, for example, avoiding undesirable spillage or leakage ofthermosetting resin 252 on component parts of system 100 and/or oncomposite part 102 being manufactured. Additionally or alternatively, itmay be desirable for continuous flexible line 106 to have a greatervolume of thermosetting resin 252 along a subset of its length and alesser volume of thermosetting resin 252, or even no thermosetting resin252, along a different subset of its length, such as to result indesired properties of composite part 102.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 5,resin-metering system 256 comprises at least one sensor 254, configuredto detect a level of thermosetting resin 252 in delivery guide 112. Thepreceding subject matter of this paragraph characterizes example 18 ofthe present disclosure, wherein example 18 also includes the subjectmatter according to example 17, above.

One or more sensors 254 provide data for resin-metering system 256 tobase its active control of the flow of first part 253 and second part255 of thermosetting resin 252.

Any suitable sensors 254 may be provided, including sensors 254 that areconfigured to detect the presence of first part 253 and/or second part255. Sensors 254 may be optical, capacitive, and/or ultrasonic, asexamples.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 5, atleast one sensor 254 comprises high-level sensor 101, configured todetect when the level of thermosetting resin 252 is at or above an upperthreshold level in delivery guide 112. Resin-metering system 256 isconfigured to reduce the flow of first part 253 and second part 255 ofthermosetting resin 252 responsive to thermosetting resin 252 being ator above the upper threshold level in delivery guide 112. The precedingsubject matter of this paragraph characterizes example 19 of the presentdisclosure, wherein example 19 also includes the subject matteraccording to example 18, above.

By including high-level sensor 101, resin-metering system 256 mayactively control the flow of first part 253 and/or second part 255 toavoid unwanted overflow of first part 253 and/or second part 255upstream of delivery guide 112, such as into feed mechanism 104, whichmay be undesirable.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 5, atleast one sensor 254 comprises low-level sensor 260, configured todetect when the level of thermosetting resin 252 is at or below a lowerthreshold level in delivery guide 112. Resin-metering system 256 isconfigured to increase the flow of first part 253 and second part 255 ofthermosetting resin 252 responsive to thermosetting resin 252 being ator below the lower threshold level in delivery guide 112. The precedingsubject matter of this paragraph characterizes example 20 of the presentdisclosure, wherein example 20 also includes the subject matteraccording to any one of examples 18 or 19, above.

By including low-level sensor 260, resin-metering system 256 mayactively control the flow of first part 253 and/or second part 255 toensure that sufficient thermosetting resin 252 is being applied tonon-resin component 108. For example, if low-level sensor 260 detectsnone of first part 253, second part 255 and/or thermosetting resin 252or detects an insufficient level of first part 253, second part 255and/or thermosetting resin 252, then resin-metering system 256 mayincrease the flow of first part 253 and/or second part 255 to deliveryguide 112 and thus to non-resin component 108.

Referring to FIG. 5, low-level sensor 260 is positioned upstream fromsecond inlet 250 and third inlet 257. The preceding subject matter ofthis paragraph characterizes example 21 of the present disclosure,wherein example 21 also includes the subject matter according to example20, above.

Positioning low-level sensor 260 upstream from second inlet 250 andthird inlet 257 may facilitate the detection of a low level of firstpart 253, second part 255, and/or thermosetting resin 252 prior to thelevel being unacceptably low, such that it results in less thansufficient saturation of non-resin component 108.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 5,low-level sensor 260 is positioned downstream from second inlet 250 andthird inlet 257. The preceding subject matter of this paragraphcharacterizes example 22 of the present disclosure, wherein example 22also includes the subject matter according to example 20, above.

Positioning low-level sensor 260 downstream from second inlet 250 andthird inlet 257 may facilitate detection of an unacceptably low level offirst part 253, second part 255, and/or thermosetting resin 252, so thatresin-metering system 256 may take corrective action.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 5, atleast one sensor 254 comprises saturation sensor 276, positioned todetect a level of saturation of non-resin component 108 withthermosetting resin 252 prior to exiting delivery guide 112. Thepreceding subject matter of this paragraph characterizes example 23 ofthe present disclosure, wherein example 23 also includes the subjectmatter according to any one of examples 18-22, above.

By including saturation sensor 276 in a position to detect a level ofsaturation of non-resin component 108 prior to continuous flexible line106 exiting delivery guide 112, resin-metering system 256 may be used toensure that continuous flexible line 106 is always at a desired, orabove a minimum threshold level of, saturation.

Referring to FIG. 1, resin-metering system 256 further comprises firstpump 265, configured to selectively increase and decrease the flow offirst part 253 of thermosetting resin 252 responsive to input from atleast one sensor 254. Resin-metering system 256 further comprises secondpump 267, configured to selectively increase and decrease the flow ofsecond part 255 of thermosetting resin 252 responsive to input from atleast one sensor 254. The preceding subject matter of this paragraphcharacterizes example 24 of the present disclosure, wherein example 24also includes the subject matter according to any one of examples 18-23,above.

Pump 265 and pump 267 provide for selective increase and/or decrease inthe flow of first part 253 and second part 255 of thermosetting resin252 based on input from one or more sensors 254.

Referring to FIG. 1, system 100 further comprises external mixingstructure 263, configured to operatively combine first part 253 andsecond part 255 of thermosetting resin 252 outside of delivery guide112. Second inlet 250 is configured to receive thermosetting resin 252from external mixing structure 263. The preceding subject matter of thisparagraph characterizes example 25 of the present disclosure, whereinexample 25 also includes the subject matter according to example 1,above.

By having external mixing structure 263, that is mixing structureoutside of delivery guide 112, delivery guide 112 may be smaller than inexamples with internal mixing structure. Moreover, external mixingstructure 263 may comprise an off-the-shelf product that is easilyreplaced during the use and/or lifetime of system 100.

Referring to FIG. 1 external mixing structure 263 comprises one or moremixing guides 261, configured to intermix first part 253 ofthermosetting resin 252 and second part 255 of thermosetting resin 252.The preceding subject matter of this paragraph characterizes example 26of the present disclosure, wherein example 26 also includes the subjectmatter according to example 25, above.

Mixing guides 261, when present, facilitate mixing of first part 253 andsecond part 255 of thermosetting resin 252. Mixing guides 261 may takeany suitable form, such as to impart turbulent flow and/or change ofdirections of first part 253 and/or second part 255 to ensure adequatemixing thereof.

Referring to FIG. 1, external mixing structure 263 comprises anoff-the-shelf resin-mixing nozzle. The preceding subject matter of thisparagraph characterizes example 27 of the present disclosure, whereinexample 27 also includes the subject matter according to any one ofexamples 25 or 26, above.

Use of an off-the-shelf mixing nozzle may facilitate easy andcost-effective replacement of external mixing structure 263, therebyavoiding having to replace delivery guide 112.

Illustrative, non-exclusive examples of off-the-shelf resin mixingnozzles includes those marketed for epoxy mixing, such as under the 3M™,LOCTITE™, DEVCON™, and SKIA™ brands.

Referring to FIG. 1, system 100 further comprises first vessel 262,configured to dispense first part 253 of thermosetting resin 252 toexternal mixing structure 263. System 100 further comprises secondvessel 272, configured to dispense second part 255 of thermosettingresin 252 to external mixing structure 263. The preceding subject matterof this paragraph characterizes example 28 of the present disclosure,wherein example 28 also includes the subject matter according to any oneof examples 25-27, above.

Vessel 262 provides a volume of first part 253 of thermosetting resin252, and vessel 272 provides a volume of second part 255 ofthermosetting resin 252. Moreover, vessel 262 and vessel 272 may bereplenished during manufacture of composite part 102 and optionally maybe replenished with different first parts 253 and second parts 255,respectively, during manufacture of composite part 102, such as tocreate desired properties at different locations within composite part102.

Additionally or alternatively, more than one vessel 262 and/or more thanone vessel 272 may be provided, with individual vessels 262 and/orindividual vessels 272, each holding different first parts 253 and/ordifferent second parts 255, respectively, for selective delivery tosecond inlet 250 and third inlet 257, respectively.

Referring to FIG. 1, system 100 further comprises resin-metering system256, configured to actively control a flow of first part 253 ofthermosetting resin 252 to external mixing structure 263 and to activelycontrol a flow of second part 255 of thermosetting resin 252 to externalmixing structure 263, and thus to actively control a flow ofthermosetting resin 252 to second inlet 250 of delivery guide 112. Thepreceding subject matter of this paragraph characterizes example 29 ofthe present disclosure, wherein example 29 also includes the subjectmatter according to example 28, above.

By actively controlling a flow of first part 253 and second part 255 toexternal mixing structure 263, a desired volume of thermosetting resin252 may be delivered to delivery guide 112 and applied to non-resincomponent 108. Moreover, over supplying thermosetting resin 252 todelivery guide 112 may be avoided, for example, avoiding undesirablespillage or leakage of thermosetting resin 252 on component parts ofsystem 100 and/or on composite part 102 being manufactured. Additionallyor alternatively, it may be desirable for continuous flexible line 106to have a greater volume of thermosetting resin 252 along a subset ofits length and a lesser volume of thermosetting resin 252, or even nothermosetting resin 252, along a different subset of its length, such asto result in desired properties of composite part 102.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 4,resin-metering system 256 comprises at least one sensor 254, configuredto detect a level of thermosetting resin 252 in delivery guide 112. Thepreceding subject matter of this paragraph characterizes example 30 ofthe present disclosure, wherein example 30 also includes the subjectmatter according to example 29, above.

One or more sensors 254 provide data for resin-metering system 256 tobase its active control of the flow of first part 253 and second part255 of thermosetting resin 252.

Any suitable sensors 254 may be provided, including sensors 254 that areconfigured to detect the presence of first part 253 and/or second part255. Sensors 254 may be optical, capacitive, and/or ultrasonic, asexamples.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 4, atleast one sensor 254 comprises high-level sensor 101, configured todetect when the level of thermosetting resin 252 is at or above an upperthreshold level in delivery guide 112. Resin-metering system 256 isconfigured to reduce the flow of first part 253 and second part 255 ofthe thermosetting resin 252 responsive to thermosetting resin 252 beingat or above the upper threshold level in delivery guide 112. Thepreceding subject matter of this paragraph characterizes example 31 ofthe present disclosure, wherein example 31 also includes the subjectmatter according to example 30, above.

By including high-level sensor 101, resin-metering system 256 mayactively control the flow of thermosetting resin 252 to delivery guide112 to avoid unwanted overflow of thermosetting resin 252 upstream ofdelivery guide 112, such as into feed mechanism 104, which may beundesirable.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 4, atleast one sensor 254 comprises low-level sensor 260, configured todetect when the level of thermosetting resin 252 is at or below a lowerthreshold level in delivery guide 112. Resin-metering system 256 isconfigured to increase the flow of first part 253 and second part 255 ofthermosetting resin 252 responsive to thermosetting resin 252 being ator below the lower threshold level in delivery guide 112. The precedingsubject matter of this paragraph characterizes example 32 of the presentdisclosure, wherein example 32 also includes the subject matteraccording to any one of examples 30 or 31, above.

By including low-level sensor 260, resin-metering system 256 mayactively control the flow of thermosetting resin 252 to delivery guide112 to ensure that sufficient thermosetting resin 252 is being appliedto non-resin component 108. For example, if low-level sensor 260 detectsnone of thermosetting resin 252 or detects an insufficient level ofthermosetting resin 252, then resin-metering system 256 may increase theflow of first part 253 and/or second part 255 to external mixingstructure 263 and thus thermosetting resin 252 to delivery guide 112 andnon-resin component 108.

Referring to FIG. 4, low-level sensor 260 is positioned upstream fromsecond inlet 250. The preceding subject matter of this paragraphcharacterizes example 33 of the present disclosure, wherein example 33also includes the subject matter according to example 32, above.

Positioning low-level sensor 260 upstream from second inlet 250 mayfacilitate the detection of a low level of thermosetting resin 252 priorto the level being unacceptably low, such that it results in less thansufficient saturation of non-resin component 108.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 4,low-level sensor 260 is positioned downstream from second inlet 250. Thepreceding subject matter of this paragraph characterizes example 34 ofthe present disclosure, wherein example 34 also includes the subjectmatter according to example 32, above.

Positioning low-level sensor 260 downstream from second inlet 250 mayfacilitate detection of an unacceptably low level of thermosetting resin252, so that resin-metering system 256 may take corrective action.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 4, atleast one sensor 254 comprises saturation sensor 276, positioned todetect a level of saturation of non-resin component 108 withthermosetting resin 252 prior to exiting delivery guide 112. Thepreceding subject matter of this paragraph characterizes example 35 ofthe present disclosure, wherein example 35 also includes the subjectmatter according to any one of examples 30-34, above.

By including saturation sensor 276 in a position to detect a level ofsaturation of non-resin component 108 prior to continuous flexible line106 exiting delivery guide 112, resin-metering system 256 may be used toensure that continuous flexible line 106 is always at a desired, orabove a minimum threshold level of, saturation.

Referring to FIG. 1, resin-metering system 256 further comprises firstpump 265, configured to selectively increase and decrease the flow offirst part 253 of thermosetting resin 252 responsive to input from atleast one sensor 254. Resin-metering system 256 further comprises secondpump 267, configured to selectively increase and decrease the flow ofsecond part 255 of thermosetting resin 252 responsive to input from atleast one sensor 254. The preceding subject matter of this paragraphcharacterizes example 36 of the present disclosure, wherein example 36also includes the subject matter according to any one of examples 30-35,above.

Pump 265 and pump 267 provide for selective increase and/or decrease inthe flow of first part 253 and second part 255 of thermosetting resin252 based on input from one or more sensors 254.

Referring to FIG. 1, delivery guide 112 is configured to be selectivelyreplaced. The preceding subject matter of this paragraph characterizesexample 37 of the present disclosure, wherein example 37 also includesthe subject matter according to any one of examples 1-36, above.

Accordingly, if and when thermosetting resin 252 cures or otherwisehardens within delivery guide 112, it may be replaced with a newdelivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 6 and 7,non-resin component 108 of continuous flexible line 106 comprises one ormore of a fiber, a carbon fiber, a glass fiber, a synthetic organicfiber, an aramid fiber, a natural fiber, a wood fiber, a boron fiber, asilicon-carbide fiber, an optical fiber, a fiber bundle, a fiber tow, afiber weave, a wire, a metal wire, a conductive wire, or a wire bundle.The preceding subject matter of this paragraph characterizes example 38of the present disclosure, wherein example 38 also includes the subjectmatter according to any one of examples 1-37, above.

Inclusion of a fiber or fibers in continuous flexible line 106 permitsfor selecting desired properties of composite part 102. Moreover,selection of specific materials of fibers and/or selection of specificconfigurations of fibers (e.g., a bundle, a tow, and/or a weave) maypermit for precise selection of desired properties of composite part102. Example properties of composite parts 102 include strength,stiffness, flexibility, ductility, hardness, electrical conductivity,thermal conductivity, etc. Non-resin component 108 is not limited to theidentified examples, and other types of non-resin component 108 may beused.

Referring to FIG. 1, system 100 further comprises origin 126 ofnon-resin component 108. The preceding subject matter of this paragraphcharacterizes example 39 of the present disclosure, wherein example 39also includes the subject matter according to any one of examples 1-38,above.

System 100, with origin 126, includes the material itself that definesnon-resin component 108. When provided, origin 126 may provide one ormore non-resin components 108, such as including a first non-resincomponent 108 with first desired properties and a second non-resincomponent 108 with second desired properties that are different from thefirst desired properties. For example, when more than one non-resincomponent 108 is provided, one or more may be selected for desiredproperties of composite part 102.

Referring to FIG. 1, origin 126 of non-resin component 108 comprisesspool 128 of non-resin component 108. The preceding subject matter ofthis paragraph characterizes example 40 of the present disclosure,wherein example 40 also includes the subject matter according to example39, above.

Origin 126 in the form of spool 128 may provide a significant length ofnon-resin component 108 in a compact volume that is readily replenishedor replaced during a manufacturing operation. Other forms for origin 126also are within the scope of the present disclosure and are not limitedto spool 128.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 8-11, 14,21, and 23-28, system 100 further comprises source 116 of curing energy118. Source 116 is configured to deliver curing energy 118 at least toportion 124 of segment 120 of continuous flexible line 106 after segment120 of continuous flexible line 106 exits delivery guide 112. Thepreceding subject matter of this paragraph characterizes example 41 ofthe present disclosure, wherein example 41 also includes the subjectmatter according to any one of examples 1-40, above.

Inclusion of source 116 provides a mechanism for thermosetting resincomponent 110 to be at least partially cured, and optionally fullycured, as continuous flexible line 106 is being deposited relative tosurface 114 via delivery guide 112. That is, composite part 102 is atleast partially cured, and in some examples fully cured, as it is beingmanufactured, or in situ.

As illustrative, non-exclusive examples, thermosetting resin 252, andthus thermosetting resin component 110 may be configured to be at leastpartially cured, or hardened, when curing energy 118 in the form of heatis delivered via radiation, convention, and/or conduction.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 8-11, 14,21, and 23-28, source 116 of curing energy 118 is configured to delivercuring energy 118 at least to portion 124 of segment 120 of continuousflexible line 106 as feed mechanism 104 pushes continuous flexible line106 out of delivery guide 112 toward print path 122 and after segment120 of continuous flexible line 106 is deposited along print path 122.The preceding subject matter of this paragraph characterizes example 42of the present disclosure, wherein example 42 also includes the subjectmatter according to example 41, above.

By delivering curing energy 118 to portion 124 of segment 120 ofcontinuous flexible line 106 after segment 120 is deposited by deliveryguide 112, thermosetting resin component 110 within portion 124 is atleast further cured, so that portion 124 is effectively fixed in adesired place relative to the remainder of segment 120 having beenalready deposited by delivery guide 112. In other words, source 116provides for in situ curing of composite part 102 as it is beingmanufactured by system 100.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 8-11, 14,21, and 23-28, source 116 of curing energy 118 is configured to delivera predetermined or actively determined amount of curing energy 118 at acontrolled rate at least to portion 124 of segment 120 of continuousflexible line 106. The preceding subject matter of this paragraphcharacterizes example 43 of the present disclosure, wherein example 43also includes the subject matter according to any one of examples 41 or42, above.

As a result of delivering a predetermined or actively determined amountof curing energy 118 at a controlled rate, a desired level, or degree,of cure may be established with respect to portion 124 of segment 120 atany given time during manufacture of composite part 102. For example, itmay be desirable to cure one portion 124 greater than or less thananother portion 124 during manufacture of composite part 102. Apredetermined amount of curing energy 118 may be based, e.g., onthermosetting resin 252 used for thermosetting resin component 110. Anactively determined amount of curing energy 118 may be based, e.g., onreal-time data sensed from continuous flexible line 106 as it is beingdeposited, including (but not limited to) hardness, color, temperature,glow, etc.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 21 and23-28, source 116 of curing energy 118 comprises one or more curinglasers 134. The preceding subject matter of this paragraph characterizesexample 44 of the present disclosure, wherein example 44 also includesthe subject matter according to any one of examples 41-43, above.

Inclusion of one or more curing lasers 134 facilitates a concentratedand directed stream of curing energy 118, such that curing energy 118may be selectively and precisely directed at portion 124 of segment 120during manufacture of composite part 102.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 21 and23-28, source 116 of curing energy 118 comprises one or moreultraviolet-light sources, infrared-light sources, or x-ray sources. Thepreceding subject matter of this paragraph characterizes example 45 ofthe present disclosure, wherein example 45 also includes the subjectmatter according to any one of examples 41-44, above.

Inclusion of one or more ultraviolet-light sources, infrared-lightsources, or x-ray sources permits for use of thermosetting resins 252for thermosetting resin component 110 that are configured to be curedvia radiation from ultraviolet light, infrared light, or x-rays.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 21 and23-28, source 116 of curing energy 118 comprises one or more visiblelight sources. The preceding subject matter of this paragraphcharacterizes example 46 of the present disclosure, wherein example 46also includes the subject matter according to any one of examples 41-45,above.

Inclusion of one or more visible light sources permits for use ofthermosetting resins 252 for thermosetting resin component 110 that areconfigured to be cured via radiation from visible light.

Referring to FIG. 1, source 116 of curing energy 118 comprises heatsource 136. The preceding subject matter of this paragraph characterizesexample 47 of the present disclosure, wherein example 47 also includesthe subject matter according to any one of examples 41-46, above.

Inclusion of heat source 136 permits for use of thermosetting resins 252for thermosetting resin component 110 that are configured to be curedvia heat delivered by heat source 136.

Referring to FIG. 1, heat source 136 comprises convective heat source247. The preceding subject matter of this paragraph characterizesexample 48 of the present disclosure, wherein example 48 also includesthe subject matter according to example 47, above.

Inclusion of convective heat source 247 permits for use of thermosettingresins 252 for thermosetting resin component 110 that are configured tobe cured via heat delivered by convection.

Referring generally to FIG. 1, curing energy 118 comprises a hot gasstream. The preceding subject matter of this paragraph characterizesexample 49 of the present disclosure, wherein example 49 also includesthe subject matter according to example 48, above.

A hot gas stream may be an effective way to cure thermosetting resincomponent 110, depending on the specific configuration of thermosettingresin component 110. Moreover, production of a hot gas stream may beless expensive to implement than, for example, curing laser 134 as partof system 100.

Referring to FIG. 1, heat source 136 comprises radiative heat source245. The preceding subject matter of this paragraph characterizesexample 50 of the present disclosure, wherein example 50 also includesthe subject matter according to any one of examples 47-49, above.

Inclusion of radiative heat source 245 permits for use of thermosettingresins 252 for thermosetting resin component 110 that are configured tobe cured via heat delivered by radiation.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 22, system100 further comprises chamber 258. Delivery guide 112 and feed mechanism104 are positioned within chamber 258. Delivery guide 112 is configuredto deposit segment 120 of continuous flexible line 106 along print path122 within chamber 258. Heat source 136 is configured to heat chamber258. The preceding subject matter of this paragraph characterizesexample 51 of the present disclosure, wherein example 51 also includesthe subject matter according to any one of examples 47-50, above.

Providing chamber 258, within which continuous flexible line 106 isdeposited via delivery guide 112, and heating chamber 258 to curethermosetting resin component 110 may provide an efficient way to curethermosetting resin component 110 via heat without expensive andcomplicated mechanisms that require concentrated and directed heat atsegment 120.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 22,chamber 258 is one of positively pressurized or negatively pressurizedrelative to atmospheric pressure. The preceding subject matter of thisparagraph characterizes example 52 of the present disclosure, whereinexample 52 also includes the subject matter according to example 51,above.

Depending on the configuration of composite part 102 being manufactured,it may be desirable to increase and/or decrease the pressure withinchamber 258 during curing to obtain desirable properties of compositepart 102.

Chamber 258 may be described as, or as comprising or as being comprisedby, an autoclave.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 12-16,23, and 25, heat source 136 comprises conductive heat source 249. Thepreceding subject matter of this paragraph characterizes example 53 ofthe present disclosure, wherein example 53 also includes the subjectmatter according to any one of examples 47-52, above.

Inclusion of conductive heat source 249 permits for use of thermosettingresins 252 for thermosetting resin component 110 that are configured tobe cured via heat delivered by conduction, such as by conductive heatsource 249 being placed in direct contact with portion 124 of segment120 of continuous flexible line 106 after segment 120 of continuousflexible line 106 exits delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 12-16,23, and 25, conductive heat source 249 comprises resistive heater 251.The preceding subject matter of this paragraph characterizes example 54of the present disclosure, wherein example 54 also includes the subjectmatter according to example 53, above.

Inclusion of resistive heater 251 may be an efficient and inexpensiveoption for generating heat for curing thermosetting resin component 110during manufacture of composite part 102 by system 100.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 14-16,23, and 25, system 100 further comprises compactor 138, operativelycoupled to delivery guide 112. Compactor 138 is configured to impart acompaction force at least to section 180 of segment 120 of continuousflexible line 106 after segment 120 of continuous flexible line 106exits delivery guide 112. Compactor 138 comprises conductive heat source249. The preceding subject matter of this paragraph characterizesexample 55 of the present disclosure, wherein example 55 also includesthe subject matter according to any one of examples 53 or 54, above.

Compactor 138 compacts adjacent layers of continuous flexible line 106that have been deposited by delivery guide 112 along print path 122.Moreover, compactor 138 is in direct contact with segment 120 to impartthe compaction force thereto, and therefore may deliver heat viaconduction directly to segment 120.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 12-14,23, and 25, compactor 138 comprises compaction roller 182, havingcompaction-roller surface 184 that is configured to roll over at leastsection 180 of segment 120 of continuous flexible line 106 after segment120 of continuous flexible line 106 exits delivery guide 112.Compaction-roller surface 184 is heated by conductive heat source 249.The preceding subject matter of this paragraph characterizes example 56of the present disclosure, wherein example 56 also includes the subjectmatter according to example 55, above.

Compaction roller 182, compared to alternative examples of compactor138, may reduce the axial movement of thermosetting resin component 110along segment 120 during compaction. Additionally, compared toalternative examples of compactor 138, compaction roller 182 may providea more desirable normal, or perpendicular, component of the compactionforce.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 12,compaction-roller surface 184 is textured. The preceding subject matterof this paragraph characterizes example 57 of the present disclosure,wherein example 57 also includes the subject matter according to example56, above.

When compaction-roller surface 184 is textured, compaction-rollersurface 184 imparts a texture to segment 120 or abrades segment 120,providing it with an increased surface area for better adhesion of asubsequent layer of continuous flexible line 106 deposited against it.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 13,compaction-roller surface 184 is shaped to impart a predeterminedcross-sectional shape at least to section 180 of segment 120 ofcontinuous flexible line 106 after segment 120 of continuous flexibleline 106 exits delivery guide 112. The preceding subject matter of thisparagraph characterizes example 58 of the present disclosure, whereinexample 58 also includes the subject matter according to any one ofexamples 56 or 57, above.

It may be desirable, in some applications, to impart a predeterminedcross-sectional shape to continuous flexible line 106 as it is beingdeposited by delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 15,compactor 138 comprises compaction wiper 185, having wiper drag surface186 that is configured to drag against at least section 180 of segment120 of continuous flexible line 106 after segment 120 of continuousflexible line 106 exits delivery guide 112. Wiper drag surface 186 isheated by conductive heat source 249. The preceding subject matter ofthis paragraph characterizes example 59 of the present disclosure,wherein example 59 also includes the subject matter according to example55, above.

Compaction wiper 185, compared to alternative examples of compactor 138,may increase the axial movement of thermosetting resin component 110along segment 120 during compaction.

Referring generally to FIG. 1, wiper drag surface 186 is textured. Thepreceding subject matter of this paragraph characterizes example 60 ofthe present disclosure, wherein example 60 also includes the subjectmatter according to example 59, above.

When drag surface 186 is textured, drag surface 186 imparts a texture tosegment 120 or abrades segment 120, providing it with an increasedsurface area for better adhesion of a subsequent layer of continuousflexible line 106 deposited against it.

Referring generally to FIG. 1, wiper drag surface 186 is shaped toimpart a predetermined cross-sectional shape to segment 120 ofcontinuous flexible line 106 after segment 120 of continuous flexibleline 106 exits delivery guide 112. The preceding subject matter of thisparagraph characterizes example 61 of the present disclosure, whereinexample 61 also includes the subject matter according to any one ofexamples 59 or 60, above.

As mentioned, it may be desirable, in some applications, to impart apredetermined cross-sectional shape to continuous flexible line 106 asit is being deposited by delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 14, 23,and 25, compactor 138 is biased toward section 180 of segment 120 ofcontinuous flexible line 106. The preceding subject matter of thisparagraph characterizes example 62 of the present disclosure, whereinexample 62 also includes the subject matter according to any one ofexamples 55-61, above.

By being biased toward section 180, compactor 138 imparts a desiredcompaction force against section 180.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 14, 23,and 25, compactor 138 is rotatable relative to delivery guide 112. Thepreceding subject matter of this paragraph characterizes example 63 ofthe present disclosure, wherein example 63 also includes the subjectmatter according to any one of examples 55-62, above.

By being rotatable relative to delivery guide 112, compactor 138 may beselectively positioned to impart its compaction force against section180 of segment 120 as delivery guide 112 moves, including as it changesdirections, relative to surface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 14, 23,and 25, compactor 138 is configured to trail delivery guide 112 whendelivery guide 112 moves relative to surface 114. The preceding subjectmatter of this paragraph characterizes example 64 of the presentdisclosure, wherein example 64 also includes the subject matteraccording to any one of examples 55-63, above.

By trailing delivery guide 112, compactor 138 is selectively positionedto impart its compaction force against section 180 of segment 120directly following section 180 exiting delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 23 and25, system 100 further comprises pivoting arm 152, coupled relative todelivery guide 112 such that pivoting arm 152 trails delivery guide 112as delivery guide 112 moves relative to surface 114. Compactor 138 iscoupled to pivoting arm 152. The preceding subject matter of thisparagraph characterizes example 65 of the present disclosure, whereinexample 65 also includes the subject matter according to any one ofexamples 55-64, above.

Pivoting arm 152 provides for selective pivoting of compactor 138relative to delivery guide 112. Accordingly, compactor 138 may beselectively positioned to impart its compaction force against section180 of segment 120 as delivery guide 112 moves, including as it changesdirections, relative to surface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 23 and25, system 100 further comprises pivoting-arm actuator 188, operativelycoupled to pivoting arm 152 and configured to actively control arotational position of pivoting arm 152 relative to delivery guide 112as delivery guide 112 moves relative to surface 114. The precedingsubject matter of this paragraph characterizes example 66 of the presentdisclosure, wherein example 66 also includes the subject matteraccording to example 65, above.

Pivoting-arm actuator 188 provides for selective pivoting of pivotingarm 152 and thus of compactor 138 relative to delivery guide 112.Accordingly, compactor 138 may be selectively positioned to impart itscompaction force against section 180 of segment 120 as delivery guide112 moves, including as it changes directions, relative to surface 114and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 23 and25, pivoting-arm actuator 188 is configured to actively coordinate therotational position of pivoting arm 152 with movement of delivery guide112 relative to surface 114. The preceding subject matter of thisparagraph characterizes example 67 of the present disclosure, whereinexample 67 also includes the subject matter according to example 66,above.

Accordingly, compactor 138 may be selectively and actively positioned toimpart its compaction force against section 180 of segment 120 asdelivery guide 112 moves, including as it changes directions, relativeto surface 114 and/or vice versa.

Referring to FIG. 16, compactor 138 comprises skirt 190, coupled todelivery guide 112. Skirt 190 comprises skirt drag surface 192 that ispositioned to drag against at least section 180 of segment 120 ofcontinuous flexible line 106 after segment 120 of continuous flexibleline 106 exits delivery guide 112. Skirt drag surface 192 is heated byconductive heat source 249. The preceding subject matter of thisparagraph characterizes example 68 of the present disclosure, whereinexample 68 also includes the subject matter according to example 55,above.

Skirt 190 extends from delivery guide 112 and circumferentially aroundoutlet 206. Accordingly, regardless of a direction of movement ofdelivery guide 112 relative to surface 114, and/or vice versa, skirt 190is positioned to compact section 180 of segment 120 of continuousflexible line 106 as it is being deposited.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23, system100 further comprises surface roughener 144, operatively coupled todelivery guide 112. Surface roughener 144 is configured to abrade atleast section 194 of segment 120 of continuous flexible line 106 aftersegment 120 of continuous flexible line 106 exits delivery guide 112.Surface roughener 144 comprises conductive heat source 249. Thepreceding subject matter of this paragraph characterizes example 69 ofthe present disclosure, wherein example 69 also includes the subjectmatter according to any one of examples 53-68, above.

Surface roughener 144 abrades section 194, providing it with anincreased surface area for better adhesion of a subsequent layerdeposited against it. Moreover, surface roughener 144 is in directcontact with segment 120 to abrade section 194, and therefore maydeliver heat via conduction directly to segment 120.

Referring generally to FIG. 1, surface roughener 144 comprisesroughening roller 196 having roughening-roller surface 198 that isconfigured to rotationally abrade at least section 194 of segment 120 ofcontinuous flexible line 106 after segment 120 of continuous flexibleline 106 exits delivery guide 112. Roughening-roller surface 198 isheated by conductive heat source 249. The preceding subject matter ofthis paragraph characterizes example 70 of the present disclosure,wherein example 70 also includes the subject matter according to example69, above.

Roughening roller 196, compared to alternative examples of surfaceroughener 144, may reduce the axial movement of thermosetting resincomponent 110 along segment 120 during abrasion thereof. Moreover,roughening roller surface 198, by being heated by conductive heat source249 and rolling against segment 120 may provide for efficient heattransfer, and thus curing, of section 194.

Referring generally to FIG. 1, roughening-roller surface 198 is shapedto impart a predetermined cross-sectional shape to segment 120 ofcontinuous flexible line 106 after segment 120 of continuous flexibleline 106 exits delivery guide 112. The preceding subject matter of thisparagraph characterizes example 71 of the present disclosure, whereinexample 71 also includes the subject matter according to example 70,above.

It may be desirable, in some applications, to impart a predeterminedcross-sectional shape to continuous flexible line 106 as it is beingdeposited by delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23,surface roughener 144 comprises roughening drag surface 200 that isconfigured to translationally abrade at least section 194 of segment 120of continuous flexible line 106 after segment 120 of continuous flexibleline 106 exits delivery guide 112. Roughening drag surface 200 is heatedby conductive heat source 249. The preceding subject matter of thisparagraph characterizes example 72 of the present disclosure, whereinexample 72 also includes the subject matter according to example 69,above.

Roughening drag surface 200, compared to alternative examples of surfaceroughener 144, may increase the axial movement of thermosetting resincomponent 110 along segment 120 during abrasion thereof. Moreover, dragsurface 200, by being heated by conductive heat source 249 and draggingagainst segment 120 may provide for efficient heat transfer, and thuscuring, of section 194.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23,surface roughener 144 is biased toward section 194 of segment 120 ofcontinuous flexible line 106 after segment 120 of continuous flexibleline 106 exits delivery guide 112. The preceding subject matter of thisparagraph characterizes example 73 of the present disclosure, whereinexample 73 also includes the subject matter according to any one ofexamples 69-72, above.

By being biased toward section 194, surface roughener 144 imparts adesired abrasion force against section 194.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23,surface roughener 144 is rotatable relative to delivery guide 112. Thepreceding subject matter of this paragraph characterizes example 74 ofthe present disclosure, wherein example 74 also includes the subjectmatter according to any one of examples 69-73, above.

By being rotatable relative to delivery guide 112, surface roughener 144may be selectively positioned to abrade section 194 as delivery guide112 moves, including as it changes directions, relative to surface 114and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23,surface roughener 144 is configured to trail delivery guide 112 whendelivery guide 112 moves relative to surface 114. The preceding subjectmatter of this paragraph characterizes example 75 of the presentdisclosure, wherein example 75 also includes the subject matteraccording to any one of examples 69-74, above.

By trailing delivery guide 112, surface roughener 144 is selectivelypositioned to abrade section 194 directly following segment 120 exitingdelivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23, system100 further comprises pivoting arm 152, configured such that pivotingarm 152 trails delivery guide 112 as delivery guide 112 moves relativeto surface 114. Surface roughener 144 is coupled to pivoting arm 152.The preceding subject matter of this paragraph characterizes example 76of the present disclosure, wherein example 76 also includes the subjectmatter according to any one of examples 69-75, above.

Pivoting arm 152 provides for selective pivoting of surface roughener144 relative to delivery guide 112. Accordingly, surface roughener 144may be selectively positioned to abrade section 194 as delivery guide112 moves, including as it changes directions, relative to surface 114and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23, system100 further comprises pivoting-arm actuator 188, operatively coupled topivoting arm 152 and configured to actively control a rotationalposition of pivoting arm 152 relative to delivery guide 112 as deliveryguide 112 moves relative to surface 114. The preceding subject matter ofthis paragraph characterizes example 77 of the present disclosure,wherein example 77 also includes the subject matter according to example76, above.

Pivoting-arm actuator 188 provides for selective pivoting of pivotingarm 152 and thus of surface roughener 144 relative to delivery guide112. Accordingly, surface roughener 144 may be selectively positioned toabrade section 194 as delivery guide 112 moves, including as it changesdirections, relative to surface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23,pivoting-arm actuator 188 is configured to actively coordinate therotational position of pivoting arm 152 with movement of delivery guide112 relative to surface 114. The preceding subject matter of thisparagraph characterizes example 78 of the present disclosure, whereinexample 78 also includes the subject matter according to example 77,above.

Accordingly, surface roughener 144 may be selectively and activelypositioned to abrade section 194 as delivery guide 112 moves, includingas it changes directions, relative to surface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23, system100 further comprises compactor 138. Surface roughener 144 is positionedto abrade at least section 194 of segment 120 of continuous flexibleline 106 following compaction of at least section 194 by compactor 138.The preceding subject matter of this paragraph characterizes example 79of the present disclosure, wherein example 79 also includes the subjectmatter according to any one of examples 69-78, above.

System 100 according to example 79 includes both compactor 138 andsurface roughener 144. By having surface roughener 144 positioned toabrade section 194 following compaction by compactor 138, the abrasionof section 194 is not hindered, or dulled, by a subsequent compactionthereof. Accordingly, abrasion of section 194 has an increased surfacearea for better adhesion of a subsequent layer deposited against it.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23, system100 further comprises debris inlet 202, configured to collect debrisresulting from abrading at least section 194 of segment 120 ofcontinuous flexible line 106 with surface roughener 144. The precedingsubject matter of this paragraph characterizes example 80 of the presentdisclosure, wherein example 80 also includes the subject matteraccording to any one of examples 69-79, above.

Collection by debris inlet 202 of debris that results from abrasion ofsection 194 by surface roughener 144, avoids unwanted, loose particlesof thermosetting resin component 110 becoming trapped between adjacentdeposited layers of continuous flexible line 106 that may otherwiseresult in unwanted properties of composite part 102.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23, system100 further comprises vacuum source 203, selectively communicativelycoupled with debris inlet 202. The preceding subject matter of thisparagraph characterizes example 81 of the present disclosure, whereinexample 81 also includes the subject matter according to example 80,above.

Vacuum source 203 draws air and debris from adjacent section 194 throughdebris inlet 202.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23, system100 further comprises pivoting arm 152, coupled relative to deliveryguide 112 such that pivoting arm 152 trails delivery guide 112 asdelivery guide 112 moves relative to surface 114. Debris inlet 202 isoperatively coupled to pivoting arm 152. The preceding subject matter ofthis paragraph characterizes example 82 of the present disclosure,wherein example 82 also includes the subject matter according to any oneof examples 80 or 81, above.

By being coupled to pivoting arm 152, debris inlet 202 is selectivelypositioned to collect debris directly from adjacent section 194 asdelivery guide 112 moves relative to surface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23, system100 further comprises pivoting-arm actuator 188, operatively coupled topivoting arm 152 and configured to actively control a rotationalposition of pivoting arm 152 relative to delivery guide 112 as deliveryguide 112 moves relative to surface 114. The preceding subject matter ofthis paragraph characterizes example 83 of the present disclosure,wherein example 83 also includes the subject matter according to example82, above.

Pivoting-arm actuator 188, by actively controlling a rotational positionof pivoting arm 152 relative to delivery guide 112, ensures that debrisinlet 202 trails delivery guide 112 so that debris inlet 202 isselectively positioned to collect debris directly adjacent to section194 as delivery guide 112 moves relative to surface 114 and/or viceversa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23,pivoting-arm actuator 188 is configured to actively coordinate therotational position of pivoting arm 152 with movement of delivery guide112 relative to surface 114. The preceding subject matter of thisparagraph characterizes example 84 of the present disclosure, whereinexample 84 also includes the subject matter according to example 83,above.

Pivoting-arm actuator 188, by actively coordinating a rotationalposition of pivoting arm 152 relative to delivery guide 112, ensuresthat debris inlet 202 trails delivery guide 112 so that debris inlet 202is selectively positioned to collect debris directly adjacent to section194 as delivery guide 112 moves relative to surface 114 and/or viceversa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23, system100 further comprises pressurized-gas outlet 204, configured to dispersedebris, resulting from roughening of segment 120 of continuous flexibleline 106 by surface roughener 144, with a pressurized gas. The precedingsubject matter of this paragraph characterizes example 85 of the presentdisclosure, wherein example 85 also includes the subject matteraccording to any one of examples 69-84, above.

Dispersal by pressurized-gas outlet 204 of debris that results fromabrasion of section 194 by surface roughener 144, avoids unwanted, looseparticles of thermosetting resin component 110 becoming trapped betweenadjacent deposited layers of continuous flexible line 106 that mayotherwise result in unwanted properties of composite part 102.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23, system100 further comprises pressurized-gas source 205, selectivelycommunicatively coupled with pressurized-gas outlet 204. The precedingsubject matter of this paragraph characterizes example 86 of the presentdisclosure, wherein example 86 also includes the subject matteraccording to example 85, above.

Pressurized-gas source 205 provides a source of the pressurized gas tobe delivered to section 194 via pressurized-gas outlet 204.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23, system100 further comprises pivoting arm 152, configured such that pivotingarm 152 trails delivery guide 112 as delivery guide 112 moves relativeto surface 114. Pressurized-gas outlet 204 is operatively coupled topivoting arm 152. The preceding subject matter of this paragraphcharacterizes example 87 of the present disclosure, wherein example 87also includes the subject matter according to any one of examples 85 or86, above.

By being coupled to pivoting arm 152, pressurized-gas outlet 204 isselectively positioned to disperse debris directly from adjacent section194 as delivery guide 112 moves relative to surface 114 and/or viceversa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23, system100 further comprises pivoting-arm actuator 188, operatively coupled topivoting arm 152 and configured to actively control a rotationalposition of pivoting arm 152 relative to delivery guide 112 as deliveryguide 112 moves relative to surface 114. The preceding subject matter ofthis paragraph characterizes example 88 of the present disclosure,wherein example 88 also includes the subject matter according to example87, above.

Pivoting-arm actuator 188, by actively controlling a rotational positionof pivoting arm 152 relative to delivery guide 112, ensures thatpressurized-gas outlet 204 trails delivery guide 112 so thatpressurized-gas outlet 204 is selectively positioned to disperse debrisdirectly adjacent to section 194 as delivery guide 112 moves relative tosurface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23,pivoting-arm actuator 188 is configured to actively coordinate therotational position of pivoting arm 152 with movement of delivery guide112 relative to surface 114. The preceding subject matter of thisparagraph characterizes example 89 of the present disclosure, whereinexample 89 also includes the subject matter according to example 88,above.

Pivoting-arm actuator 188, by actively coordinating a rotationalposition of pivoting arm 152 relative to delivery guide 112, ensuresthat pressurized-gas outlet 204 trails delivery guide 112 so thatpressurized-gas outlet 204 is selectively positioned to disperse debrisdirectly adjacent to section 194 as delivery guide 112 moves relative tosurface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 23-25,system 100 further comprises pivoting arm 152, coupled relative todelivery guide 112 such that pivoting arm 152 trails delivery guide 112as delivery guide 112 moves relative to surface 114. Source 116 ofcuring energy 118 is coupled to pivoting arm 152. The preceding subjectmatter of this paragraph characterizes example 90 of the presentdisclosure, wherein example 90 also includes the subject matteraccording to any one of examples 41-54, above.

Pivoting arm 152 provides for selective pivoting of source 116 relativeto delivery guide 112. Accordingly, source 116 may be selectivelypositioned to deliver curing energy 118 to portion 124 of segment 120 asdelivery guide 112 moves, including as it changes directions, relativeto surface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 23-25,system 100 further comprises pivoting-arm actuator 188, operativelycoupled to pivoting arm 152 and configured to actively control arotational position of pivoting arm 152 relative to delivery guide 112as delivery guide 112 moves relative to surface 114. The precedingsubject matter of this paragraph characterizes example 91 of the presentdisclosure, wherein example 91 also includes the subject matteraccording to example 90, above.

Pivoting-arm actuator 188 provides for selective pivoting of pivotingarm 152 and thus of source 116 relative to delivery guide 112.Accordingly, source 116 may be selectively positioned to deliver curingenergy 118 to portion 124 of segment 120 as delivery guide 112 moves,including as it changes directions, relative to surface 114 and/or viceversa.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 23-25,pivoting-arm actuator 188 is configured to actively coordinate therotational position of pivoting arm 152 with movement of delivery guide112 relative to surface 114. The preceding subject matter of thisparagraph characterizes example 92 of the present disclosure, whereinexample 92 also includes the subject matter according to example 91,above.

Accordingly, source 116 may be selectively and actively positioned todeliver curing energy 118 to portion 124 of segment 120 as deliveryguide 112 moves, including as it changes directions, relative to surface114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 14 and23-28, source 116 of curing energy 118 is configured to trail deliveryguide 112 when delivery guide 112 moves relative to surface 114. Thepreceding subject matter of this paragraph characterizes example 93 ofthe present disclosure, wherein example 93 also includes the subjectmatter according to any one of examples 41-92, above.

By trailing delivery guide 112, source 116 is selectively positioned todeliver curing energy 118 to portion 124 of segment 120 directlyfollowing portion 124 exiting delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 10, 11,and 21, source 116 of curing energy 118 is configured to deliver ring148 of curing energy 118 intersecting segment 120 of continuous flexibleline 106. The preceding subject matter of this paragraph characterizesexample 94 of the present disclosure, wherein example 94 also includesthe subject matter according to any one of examples 41-54, above.

When ring 148 of curing energy 118 intersects segment 120, ring 148ensures that curing energy 118 is delivered to portion 124 regardless ofa direction that segment 120 is exiting delivery guide 112 as deliveryguide 112 moves relative to surface 114 and/or vice versa.

Ring 148 of curing energy 118 may be defined by any suitable processand/or structure. For example, with reference to FIG. 10, and asdiscussed herein, delivery guide 112 may comprise curing-energy passage146, and source 116 of curing energy 118 may be configured to delivercuring energy 118 through curing-energy passage 146 such that curingenergy 118 defines ring 148. Additionally or alternatively, withreference to FIG. 21, as also discussed herein, energy source 116 maycomprise at least one galvanometer mirror-positioning system 150 orother type of mirror-positioning system that is configured to deliverring 148 of curing energy 118 to portion 124 of segment 120.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 9-11,delivery guide 112 further comprises curing-energy passage 146 and linepassage 154, through which continuous flexible line 106 is delivered toprint path 122. Source 116 of curing energy 118 is configured to delivercuring energy 118 through curing-energy passage 146 at least to portion124 of segment 120 of continuous flexible line 106. Curing-energypassage 146 is optically isolated from line passage 154. The precedingsubject matter of this paragraph characterizes example 95 of the presentdisclosure, wherein example 95 also includes the subject matteraccording to any one of examples 41-54 or 94, above.

System 100 according to example 95 provides for precise direction ofcuring energy 118 to portion 124 as continuous flexible line 106 isexiting delivery guide 112. Moreover, by being optically isolated fromline passage 154, curing-energy passage 146 restricts curing energy 118,when in the form of light, from contacting continuous flexible line 106before continuous flexible line 106 exits delivery guide 112. Moreover,in examples that include resin passage 264, curing-energy passage 146 isoptically isolated from resin passage 264.

According to example 95 (referring, e.g., to FIG. 10), curing-energypassage 146 may encircle line passage 154 and may have a circular outletaround outlet 206 of line passage 154, such that the exit of curingenergy 118 from curing-energy passage 146 results in ring 148 of curingenergy 118, such as according to example 94 herein.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, source116 of curing energy 118 is not configured to move with delivery guide112. The preceding subject matter of this paragraph characterizesexample 96 of the present disclosure, wherein example 96 also includesthe subject matter according to any one of examples 41-54, above.

Such an example of system 100 may provide for a less cumbersome assemblyassociated with delivery guide 112, permitting delivery guide 112 tomore easily make micro-movements and turns, or angle changes, relativeto surface 114 and/or vice versa, such as based on the configuration ofcomposite part 102, and desired properties thereof, being manufactured.

FIG. 21 provides an example of system 100, with energy source 116comprising two galvanometer mirror-positioning systems 150 that arestatic relative to delivery guide 112 as delivery guide 112 movesrelative to surface 114, but with galvanometer mirror-positioningsystems 150 configured to deliver curing energy 118 to portion 124 ofsegment 120 of continuous flexible line 106 as it exits delivery guide112. While described herein as galvanometer mirror-positioning systems150, other systems and devices for directing curing energy 118 toportion 124 may be used and are within the scope of the presentdisclosure, such as (but not limited to) a solid-state piezoelectricmirror-positioning system.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, source116 of curing energy 118 comprises at least one galvanometermirror-positioning system 150, configured to deliver curing energy 118at least to portion 124 of segment 120 of continuous flexible line 106responsive to movement of delivery guide 112 relative to surface 114.The preceding subject matter of this paragraph characterizes example 97of the present disclosure, wherein example 97 also includes the subjectmatter according to any one of examples 41-46, above.

In other words, one or more galvanometer mirror-positioning systems 150may actively direct curing energy 118 at portion 124 of segment 120 ascontinuous flexible line 106 exits delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 8, source116 of curing energy 118 is configured to partially cure first layer 140of segment 120 of continuous flexible line 106 as at least a portion offirst layer 140 is being deposited by delivery guide 112 against surface114 and to further cure first layer 140 and to partially cure secondlayer 142 as second layer 142 is being deposited by delivery guide 112against first layer 140. The preceding subject matter of this paragraphcharacterizes example 98 of the present disclosure, wherein example 98also includes the subject matter according to any one of examples 41-97,above.

By only partially curing first layer 140 as first layer 140 is beingdeposited, first layer 140 may remain tacky, or sticky, therebyfacilitating adhesion of second layer 142 against first layer 140 assecond layer 142 is deposited against first layer 140. Then, first layer140 is further cured as second layer 142 is being partially cured fordeposition of a subsequent layer against second layer 142, and so forth.

By further curing first layer 140, it is meant that first layer 140 maybe fully cured or less than fully cured. For example, in someapplications, a less than full cure of composite part 102 may bedesirable during manufacture by system 100 to permit for subsequent workon composite part 102 before an entirety of composite part 102 is fullycured, such as with a process separate from system 100. For example,composite part 102 may be baked, heated, and/or placed in an autoclavefor final curing.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 12-16,23, and 25, system 100 further comprises compactor 138, operativelycoupled to delivery guide 112. Compactor 138 is configured to impart acompaction force at least to section 180 of segment 120 of continuousflexible line 106 after segment 120 of continuous flexible line 106exits delivery guide 112. The preceding subject matter of this paragraphcharacterizes example 99 of the present disclosure, wherein example 99also includes the subject matter according to any one of examples 1-54or 69-98, above.

Compactor 138 compacts adjacent layers of continuous flexible line 106that have been deposited by delivery guide 112 along print path 122.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 12-14,23, and 25, compactor 138 comprises compaction roller 182, havingcompaction-roller surface 184 that is configured to roll over at leastsection 180 of segment 120 of continuous flexible line 106 after segment120 of continuous flexible line 106 exits delivery guide 112. Thepreceding subject matter of this paragraph characterizes example 100 ofthe present disclosure, wherein example 100 also includes the subjectmatter according to example 99, above.

Compaction roller 182, compared to alternative examples of compactor138, may reduce the axial movement of thermosetting resin component 110along segment 120 during compaction. Additionally, compared toalternative examples of compactor 138, compaction roller 182 may providea more desirable normal, or perpendicular, component of the compactionforce.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 12,compaction-roller surface 184 is textured. The preceding subject matterof this paragraph characterizes example 101 of the present disclosure,wherein example 101 also includes the subject matter according toexample 100, above.

When compaction-roller surface 184 is textured, compaction-rollersurface 184 imparts a texture to segment 120 or abrades segment 120,providing it with an increased surface area for better adhesion of asubsequent layer of continuous flexible line 106 deposited against it.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 13,compaction-roller surface 184 is shaped to impart a predeterminedcross-sectional shape at least to section 180 of segment 120 ofcontinuous flexible line 106 after segment 120 of continuous flexibleline 106 exits delivery guide 112. The preceding subject matter of thisparagraph characterizes example 102 of the present disclosure, whereinexample 102 also includes the subject matter according to any one ofexamples 100 or 101, above.

It may be desirable, in some applications, to impart a predeterminedcross-sectional shape to continuous flexible line 106 as it is beingdeposited by delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 15,compactor 138 comprises compaction wiper 185, having wiper drag surface186 that is configured to drag against at least section 180 of segment120 of continuous flexible line 106 after segment 120 of continuousflexible line 106 exits delivery guide 112. The preceding subject matterof this paragraph characterizes example 103 of the present disclosure,wherein example 103 also includes the subject matter according toexample 99, above.

Compaction wiper 185, compared to alternative examples of compactor 138,may increase the axial movement of thermosetting resin component 110along segment 120 during compaction.

Referring generally to FIG. 1, wiper drag surface 186 is textured. Thepreceding subject matter of this paragraph characterizes example 104 ofthe present disclosure, wherein example 104 also includes the subjectmatter according to example 103, above.

When drag surface 186 is textured, drag surface 186 imparts a texture tosegment 120 or abrades segment 120, providing it with an increasedsurface area for better adhesion of a subsequent layer of continuousflexible line 106 deposited against it.

Referring generally to FIG. 1, wiper drag surface 186 is shaped toimpart a predetermined cross-sectional shape to segment 120 ofcontinuous flexible line 106 after segment 120 of continuous flexibleline 106 exits delivery guide 112. The preceding subject matter of thisparagraph characterizes example 105 of the present disclosure, whereinexample 105 also includes the subject matter according to any one ofexamples 103 or 104, above.

As mentioned, it may be desirable, in some applications, to impart apredetermined cross-sectional shape to continuous flexible line 106 asit is being deposited by delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 14, 23,and 25, compactor 138 is biased toward section 180 of segment 120 ofcontinuous flexible line 106. The preceding subject matter of thisparagraph characterizes example 106 of the present disclosure, whereinexample 106 also includes the subject matter according to any one ofexamples 99-105, above.

By being biased toward section 180, compactor 138 imparts a desiredcompaction force against section 180.

Compactor 138 may be biased toward section 180, such as by spring 181(as illustrated in FIG. 1) or another biasing member.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 14, 23,and 25, compactor 138 is rotatable relative to delivery guide 112. Thepreceding subject matter of this paragraph characterizes example 107 ofthe present disclosure, wherein example 107 also includes the subjectmatter according to any one of examples 99-106, above.

By being rotatable relative to delivery guide 112, compactor 138 may beselectively positioned to impart its compaction force against section180 of segment 120 as delivery guide 112 moves, including as it changesdirections, relative to surface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 12, 23,and 25, compactor 138 is configured to trail delivery guide 112 whendelivery guide 112 moves relative to surface 114. The preceding subjectmatter of this paragraph characterizes example 108 of the presentdisclosure, wherein example 108 also includes the subject matteraccording to any one of examples 99-107, above.

By trailing delivery guide 112, compactor 138 is selectively positionedto impart its compaction force against section 180 of segment 120directly following section 180 exiting delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 23 and25, system 100 further comprises pivoting arm 152, coupled relative todelivery guide 112 such that pivoting arm 152 trails delivery guide 112as delivery guide 112 moves relative to surface 114. Compactor 138 iscoupled to pivoting arm 152. The preceding subject matter of thisparagraph characterizes example 109 of the present disclosure, whereinexample 109 also includes the subject matter according to any one ofexamples 99-108, above.

Pivoting arm 152 provides for selective pivoting of compactor 138relative to delivery guide 112. Accordingly, compactor 138 may beselectively positioned to impart its compaction force against section180 of segment 120 as delivery guide 112 moves, including as it changesdirections, relative to surface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 23 and25, system 100 further comprises pivoting-arm actuator 188, operativelycoupled to pivoting arm 152 and configured to actively control arotational position of pivoting arm 152 relative to delivery guide 112as delivery guide 112 moves relative to surface 114. The precedingsubject matter of this paragraph characterizes example 110 of thepresent disclosure, wherein example 110 also includes the subject matteraccording to example 109, above.

Pivoting-arm actuator 188 provides for selective pivoting of pivotingarm 152 and thus of compactor 138 relative to delivery guide 112.Accordingly, compactor 138 may be selectively positioned to impart itscompaction force against section 180 of segment 120 as delivery guide112 moves, including as it changes directions, relative to surface 114and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 23 and25, pivoting-arm actuator 188 is configured to actively coordinate therotational position of pivoting arm 152 with movement of delivery guide112 relative to surface 114. The preceding subject matter of thisparagraph characterizes example 111 of the present disclosure, whereinexample 111 also includes the subject matter according to example 110,above.

Accordingly, compactor 138 may be selectively and actively positioned toimpart its compaction force against section 180 of segment 120 asdelivery guide 112 moves, including as it changes directions, relativeto surface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 16,compactor 138 comprises skirt 190, coupled to delivery guide 112. Skirt190 comprises skirt drag surface 192 that is positioned to drag againstat least section 180 of segment 120 of continuous flexible line 106after segment 120 of continuous flexible line 106 exits delivery guide112. The preceding subject matter of this paragraph characterizesexample 112 of the present disclosure, wherein example 112 also includesthe subject matter according to example 99, above.

Skirt 190 extends from delivery guide 112 and circumferentially aroundoutlet 206. Accordingly, regardless of a direction of movement ofdelivery guide 112 relative to surface 114, and/or vice versa, skirt 190is positioned to compact section 180 of segment 120 of continuousflexible line 106 as it is being deposited.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23, system100 further comprises surface roughener 144, operatively coupled todelivery guide 112. Surface roughener 144 is configured to abrade atleast section 194 of segment 120 of continuous flexible line 106 aftersegment 120 of continuous flexible line 106 exits delivery guide 112.The preceding subject matter of this paragraph characterizes example 113of the present disclosure, wherein example 113 also includes the subjectmatter according to any one of examples 1-68 or 90-112, above.

Surface roughener 144 abrades section 194, providing it with anincreased surface area for better adhesion of a subsequent layerdeposited against it.

Referring to FIG. 1, surface roughener 144 comprises roughening roller196, having roughening-roller surface 198 that is configured torotationally abrade at least section 194 of segment 120 of continuousflexible line 106 after segment 120 of continuous flexible line 106exits delivery guide 112. The preceding subject matter of this paragraphcharacterizes example 114 of the present disclosure, wherein example 114also includes the subject matter according to example 113, above.

Roughening roller 196, compared to alternative examples of surfaceroughener 144, may reduce the axial movement of thermosetting resincomponent 110 along segment 120 during abrasion thereof. Moreover,roughening roller surface 198, by being heated by conductive heat source249 and rolling against segment 120 may provide for efficient heattransfer, and thus curing, of section 194.

Referring generally to FIG. 1, roughening-roller surface 198 is shapedto impart a predetermined cross-sectional shape to segment 120 ofcontinuous flexible line 106 after segment 120 of continuous flexibleline 106 exits delivery guide 112. The preceding subject matter of thisparagraph characterizes example 115 of the present disclosure, whereinexample 115 also includes the subject matter according to example 114,above.

It may be desirable, in some applications, to impart a predeterminedcross-sectional shape to continuous flexible line 106 as it is beingdeposited by delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23,surface roughener 144 comprises roughening drag surface 200 that isconfigured to translationally abrade at least section 194 of segment 120of continuous flexible line 106 after segment 120 of continuous flexibleline 106 exits delivery guide 112. The preceding subject matter of thisparagraph characterizes example 116 of the present disclosure, whereinexample 116 also includes the subject matter according to example 113,above.

Roughening drag surface 200, compared to alternative examples of surfaceroughener 144, may increase the axial movement of thermosetting resincomponent 110 along segment 120 during abrasion thereof.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23,surface roughener 144 is biased toward section 194 of segment 120 ofcontinuous flexible line 106 after segment 120 of continuous flexibleline 106 exits delivery guide 112. The preceding subject matter of thisparagraph characterizes example 117 of the present disclosure, whereinexample 117 also includes the subject matter according to any one ofexamples 113-116, above.

By being biased toward section 194, surface roughener 144 imparts adesired abrasion force against section 194.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23,surface roughener 144 is rotatable relative to delivery guide 112. Thepreceding subject matter of this paragraph characterizes example 118 ofthe present disclosure, wherein example 118 also includes the subjectmatter according to any one of examples 113-117, above.

By being rotatable relative to delivery guide 112, surface roughener 144may be selectively positioned to abrade section 194 as delivery guide112 moves, including as it changes directions, relative to surface 114and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23,surface roughener 144 is configured to trail delivery guide 112 whendelivery guide 112 moves relative to surface 114. The preceding subjectmatter of this paragraph characterizes example 119 of the presentdisclosure, wherein example 119 also includes the subject matteraccording to any one of examples 113-118, above.

By trailing delivery guide 112, surface roughener 144 is selectivelypositioned to abrade section 194 directly following segment 120 exitingdelivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23, system100 further comprises pivoting arm 152, configured such that pivotingarm 152 trails delivery guide 112 as delivery guide 112 moves relativeto surface 114. Surface roughener 144 is coupled to pivoting arm 152.The preceding subject matter of this paragraph characterizes example 120of the present disclosure, wherein example 120 also includes the subjectmatter according to any one of examples 113-119, above.

By trailing delivery guide 112, surface roughener 144 is selectivelypositioned to abrade section 194 directly following segment 120 exitingdelivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23, system100 further comprises pivoting-arm actuator 188, operatively coupled topivoting arm 152 and configured to actively control a rotationalposition of pivoting arm 152 relative to delivery guide 112 as deliveryguide 112 moves relative to surface 114. The preceding subject matter ofthis paragraph characterizes example 121 of the present disclosure,wherein example 121 also includes the subject matter according toexample 120, above.

Pivoting-arm actuator 188 provides for selective pivoting of pivotingarm 152 and thus of surface roughener 144 relative to delivery guide112. Accordingly, surface roughener 144 may be selectively positioned toabrade section 194 as delivery guide 112 moves, including as it changesdirections, relative to surface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23,pivoting-arm actuator 188 is configured to actively coordinate therotational position of pivoting arm 152 with movement of delivery guide112 relative to surface 114. The preceding subject matter of thisparagraph characterizes example 122 of the present disclosure, whereinexample 122 also includes the subject matter according to example 121,above.

Accordingly, surface roughener 144 may be selectively and activelypositioned to abrade section 194 as delivery guide 112 moves, includingas it changes directions, relative to surface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23, system100 further comprises compactor 138. Surface roughener 144 is positionedto abrade at least section 194 of segment 120 of continuous flexibleline 106 following compaction of at least section 194 by compactor 138.The preceding subject matter of this paragraph characterizes example 123of the present disclosure, wherein example 123 also includes the subjectmatter according to any one of examples 113-122, above.

System 100 according to example 123 includes both compactor 138 andsurface roughener 144. By having surface roughener 144 positioned toabrade section 194 following compaction by compactor 138, the abrasionof section 194 is not hindered, or dulled, by a subsequent compactionthereof. Accordingly, abrasion of section 194 has an increased surfacearea for better adhesion of a subsequent layer deposited against it.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23, system100 further comprises debris inlet 202, configured to collect debrisresulting from abrading at least section 194 of segment 120 ofcontinuous flexible line 106 with surface roughener 144. The precedingsubject matter of this paragraph characterizes example 124 of thepresent disclosure, wherein example 124 also includes the subject matteraccording to any one of examples 113-123, above.

Collection by debris inlet 202 of debris that results from abrasion ofsection 194 by surface roughener 144, avoids unwanted, loose particlesof thermosetting resin component 110 becoming trapped between adjacentdeposited layers of continuous flexible line 106 that may otherwiseresult in unwanted properties of composite part 102.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23, system100 further comprises vacuum source 203, selectively communicativelycoupled with debris inlet 202. The preceding subject matter of thisparagraph characterizes example 125 of the present disclosure, whereinexample 125 also includes the subject matter according to example 124,above.

Vacuum source 203 draws air and debris from adjacent section 194 throughdebris inlet 202.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23, system100 further comprises pivoting arm 152, coupled relative to deliveryguide 112 such that pivoting arm 152 trails delivery guide 112 asdelivery guide 112 moves relative to surface 114. Debris inlet 202 isoperatively coupled to pivoting arm 152. The preceding subject matter ofthis paragraph characterizes example 126 of the present disclosure,wherein example 126 also includes the subject matter according to anyone of examples 124 or 125, above.

By being coupled to pivoting arm 152, debris inlet 202 is selectivelypositioned to collect debris directly from adjacent section 194 asdelivery guide 112 moves relative to surface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23, system100 further comprises pivoting-arm actuator 188, operatively coupled topivoting arm 152 and configured to actively control a rotationalposition of pivoting arm 152 relative to delivery guide 112 as deliveryguide 112 moves relative to surface 114. The preceding subject matter ofthis paragraph characterizes example 127 of the present disclosure,wherein example 127 also includes the subject matter according toexample 126, above.

Pivoting-arm actuator 188, by actively controlling a rotational positionof pivoting arm 152 relative to delivery guide 112, ensures that debrisinlet 202 trails delivery guide 112 so that debris inlet 202 isselectively positioned to collect debris directly adjacent to section194 as delivery guide 112 moves relative to surface 114 and/or viceversa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23,pivoting-arm actuator 188 is configured to actively coordinate therotational position of pivoting arm 152 with movement of delivery guide112 relative to surface 114. The preceding subject matter of thisparagraph characterizes example 128 of the present disclosure, whereinexample 128 also includes the subject matter according to example 127,above.

Pivoting-arm actuator 188, by actively coordinating a rotationalposition of pivoting arm 152 relative to delivery guide 112, ensuresthat debris inlet 202 trails delivery guide 112 so that debris inlet 202is selectively positioned to collect debris directly adjacent to section194 as delivery guide 112 moves relative to surface 114 and/or viceversa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23, system100 further comprises pressurized-gas outlet 204, configured to dispersedebris, resulting from roughening of segment 120 of continuous flexibleline 106 by surface roughener 144, with a pressurized gas. The precedingsubject matter of this paragraph characterizes example 129 of thepresent disclosure, wherein example 129 also includes the subject matteraccording to any one of examples 113-128, above.

Dispersal by pressurized-gas outlet 204 of debris that results fromabrasion of section 194 by surface roughener 144, avoids unwanted, looseparticles of thermosetting resin component 110 becoming trapped betweenadjacent deposited layers of continuous flexible line 106 that mayotherwise result in unwanted properties of composite part 102.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23, system100 further comprises pressurized-gas source 205, selectivelycommunicatively coupled with pressurized-gas outlet 204. The precedingsubject matter of this paragraph characterizes example 130 of thepresent disclosure, wherein example 130 also includes the subject matteraccording to example 129, above.

Pressurized-gas source 205 provides a source of the pressurized gas tobe delivered to section 194 via pressurized-gas outlet 204.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23, system100 further comprises pivoting arm 152, configured such that pivotingarm 152 trails delivery guide 112 as delivery guide 112 moves relativeto surface 114. Pressurized-gas outlet 204 is operatively coupled topivoting arm 152. The preceding subject matter of this paragraphcharacterizes example 131 of the present disclosure, wherein example 131also includes the subject matter according to any one of examples 129 or130, above.

By being coupled to pivoting arm 152, pressurized-gas outlet 204 isselectively positioned to disperse debris directly from adjacent section194 as delivery guide 112 moves relative to surface 114 and/or viceversa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23, system100 further comprises pivoting-arm actuator 188, operatively coupled topivoting arm 152 and configured to actively control a rotationalposition of pivoting arm 152 relative to delivery guide 112 as deliveryguide 112 moves relative to surface 114. The preceding subject matter ofthis paragraph characterizes example 132 of the present disclosure,wherein example 132 also includes the subject matter according toexample 131, above.

Pivoting-arm actuator 188, by actively controlling a rotational positionof pivoting arm 152 relative to delivery guide 112, ensures thatpressurized-gas outlet 204 trails delivery guide 112 so thatpressurized-gas outlet 204 is selectively positioned to disperse debrisdirectly adjacent to section 194 as delivery guide 112 moves relative tosurface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 23,pivoting-arm actuator 188 is configured to actively coordinate therotational position of pivoting arm 152 with movement of delivery guide112 relative to surface 114. The preceding subject matter of thisparagraph characterizes example 133 of the present disclosure, whereinexample 133 also includes the subject matter according to example 132,above.

Pivoting-arm actuator 188, by actively coordinating a rotationalposition of pivoting arm 152 relative to delivery guide 112, ensuresthat pressurized-gas outlet 204 trails delivery guide 112 so thatpressurized-gas outlet 204 is selectively positioned to disperse debrisdirectly adjacent to section 194 as delivery guide 112 moves relative tosurface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 4, 5, and23-31, feed mechanism 104 is coupled to delivery guide 112. Thepreceding subject matter of this paragraph characterizes example 134 ofthe present disclosure, wherein example 134 also includes the subjectmatter according to any one of examples 1-133, above.

Having feed mechanism 104 coupled to delivery guide 112 facilitates feedmechanism 104 being able to operatively push continuous flexible line106 through delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 4, 5, and23-31, delivery guide 112 extends from feed mechanism 104. The precedingsubject matter of this paragraph characterizes example 135 of thepresent disclosure, wherein example 135 also includes the subject matteraccording to any one of examples 1-134, above.

By extending from feed mechanism 104, delivery guide 112 may bepositioned for selective deposition of continuous flexible line 106 in adesired location along print path 122.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 4 and 5,delivery guide 112 further comprises outlet 206 and line passage 154,extending from first inlet 170 to outlet 206. Outlet 206 is configuredto provide an exit for continuous flexible line 106 from delivery guide112. Feed mechanism 104 comprises support frame 156 and opposing rollers157, having respective rotational axes 159. Opposing rollers 157 arerotatably coupled to support frame 156. Opposing rollers 157 areconfigured to engage opposite sides of non-resin component 108. Opposingrollers 157 are configured to selectively rotate to push non-resincomponent 108 through line passage 154 and continuous flexible line 106out of delivery guide 112. The preceding subject matter of thisparagraph characterizes example 136 of the present disclosure, whereinexample 136 also includes the subject matter according to any one ofexamples 1-135, above.

Support frame 156 provides support for component parts of feed mechanism104, including opposing rollers 157. Opposing rollers 157, whenselectively rotated, act to frictionally engage non-resin component 108,thereby feeding it between opposing rollers 157 and pushing it intoinlet 170 and through line passage 154.

Referring generally to FIGS. 4 and 5 and particularly to, e.g., FIG.29-31, opposing rollers 157 are in contact with each other. Thepreceding subject matter of this paragraph characterizes example 137 ofthe present disclosure, wherein example 137 also includes the subjectmatter according to example 136, above.

Contact between opposing rollers 157 may ensure that opposing rollers157 roll together and avoid imparting an uneven torque that would bendor otherwise create an internal curved bias to non-resin component 108as it is drawn between the rollers. Additionally or alternatively,contact between opposing rollers 157 may permit for only one of opposingrollers 157 to be directly driven by a motor, while the other ofopposing rollers 157 simply rotates as a result of being engaged withthe driven roller.

Referring generally to FIGS. 4 and 5 and particularly to, e.g., FIGS. 30and 31, each of opposing rollers 157 comprises circumferential channel161, configured to contact a portion of non-resin component 108. Thepreceding subject matter of this paragraph characterizes example 138 ofthe present disclosure, wherein example 138 also includes the subjectmatter according to any one of examples 136 or 137, above.

Inclusion of circumferential channel 161 in each of opposing rollers 157thereby creates a passage through which non-resin component 108 mayextend and provides for a greater surface area of contact betweenopposing rollers 157 and non-resin component 108, thereby facilitatingnon-resin component 108 being pushed into inlet 170 and through linepassage 154.

Referring generally to FIGS. 4 and 5 and particularly to, e.g., FIGS. 30and 31, one of opposing rollers 157 comprises circumferential channel161, configured to contact non-resin component 108. The precedingsubject matter of this paragraph characterizes example 139 of thepresent disclosure, wherein example 139 also includes the subject matteraccording to any one of examples 136 or 137, above.

As with example 138, inclusion of one circumferential channel 161creates a passage through which non-resin component 108 may extend andprovides for a greater surface area of contact between opposing rollers157 and non-resin component 108, thereby facilitating non-resincomponent 108 being pushed into inlet 170 and through line passage 154.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 29 and30, opposing rollers 157 are differently sized. The preceding subjectmatter of this paragraph characterizes example 140 of the presentdisclosure, wherein example 140 also includes the subject matteraccording to any one of examples 136-139, above.

Differently sized opposing rollers 157 may permit for efficientpackaging of feed mechanism 104. Additionally or alternatively,differently sized opposing rollers 157 may provide for a desired torquetransfer between driven roller 158 and idle roller 160.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 4 and 5,opposing rollers 157 are identically sized. The preceding subject matterof this paragraph characterizes example 141 of the present disclosure,wherein example 141 also includes the subject matter according to anyone of examples 136-139, above.

Identically sized opposing rollers 157 may permit for efficientpackaging of feed mechanism 104. Additionally or alternatively,identically sized opposing rollers 157 may provide for a desired torquetransfer between driven roller 158 and idle roller 160.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 4, 5, and29-31, feed mechanism 104 further comprises motor 162, operativelycoupled at least to one of opposing rollers 157 and configured toselectively rotate at least one of opposing rollers 157. The precedingsubject matter of this paragraph characterizes example 142 of thepresent disclosure, wherein example 142 also includes the subject matteraccording to any one of examples 136-141, above.

Motor 162 provides a motive force for rotating opposing rollers 157 forfeed mechanism 104 to push non-resin component 108 through deliveryguide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 4, 5, and29-31, opposing rollers 157 comprise driven roller 158, operativelycoupled to motor 162 and idle roller 160 biased toward driven roller 158to operatively engage opposing sides of non-resin component 108. Thepreceding subject matter of this paragraph characterizes example 143 ofthe present disclosure, wherein example 143 also includes the subjectmatter according to example 142, above.

By having idle roller 160 biased toward driven roller 158, idle roller160 need not be directly driven by a motor for feed mechanism 104 topush non-resin component 108 through delivery guide 112. Instead, idleroller 160 is rotated by idle roller 160 being engaged with drivenroller 158 and/or by being engaged with non-resin component 108, whichin turn is engaged with driven roller 158.

Idle roller 160 may be biased toward driven roller 158 by biasing member164, which may be a spring, such as a coil spring.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 29-31,feed mechanism 104 further comprises rocker arm 169. Rocker arm 169 ispivotally coupled to support frame 156. Idle roller 160 is rotationallycoupled to rocker arm 169. Rocker arm 169 is biased relative to supportframe 156 so that idle roller 160 is biased toward driven roller 158.Rocker arm 169 is configured to selectively pivot idle roller 160 awayfrom driven roller 158. The preceding subject matter of this paragraphcharacterizes example 144 of the present disclosure, wherein example 144also includes the subject matter according to example 143, above.

Rocker arm 169 provides structure for a user to engage and pivot idleroller 160 away from driven roller 158 against the bias of biasingmember 164. Accordingly, a user may selectively pivot idle roller 160 tofacilitate initial insertion of non-resin component between opposingrollers 157, such as during initial set-up of system 100 and/or tochange non-resin component 108 during manufacture of composite part 102.

As used herein, “to bias” means to continuously apply a force, which mayor may not have a constant magnitude.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 29-31,feed mechanism 104 further comprises rocker-arm adjuster 171, configuredto selectively adjust a force applied to rocker arm 169 to bias idleroller 160 toward driven roller 158. The preceding subject matter ofthis paragraph characterizes example 145 of the present disclosure,wherein example 145 also includes the subject matter according toexample 144, above.

Rocker-arm adjuster 171 permits a user to selectively adjust the biasingforce of idle roller 160 toward driven roller 158 and thus the forceapplied to non-resin component 108 between opposing rollers 157. Forexample, different magnitudes of force facilitate operation of system100 in connection with different material properties of differentconfigurations and/or different sizes of non-resin component 108 thatmay be used by system 100.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 4, 5, 29,and 30, delivery guide 112 further comprises first end portion 163,second end portion 165, and junction 167 between first end portion 163and second end portion 165. First end portion 163 is shaped to becomplementary to one of opposing rollers 157 and second end portion 165is shaped to be complementary to another of opposing rollers 157. Thepreceding subject matter of this paragraph characterizes example 146 ofthe present disclosure, wherein example 146 also includes the subjectmatter according to any one of examples 136-145, above.

Having first end portion 163 and second end portion 165 complementarywith opposing rollers 157, delivery guide 112 may be positioned in veryclose proximity to opposing rollers 157. Accordingly, when feedmechanism 104 pushes non-resin component 108 into and through deliveryguide 112, non-resin component 108 is less likely to bunch, kink, clog,or otherwise mis-feed from feed mechanism 104 to delivery guide 112.

Referring to FIGS. 4 and 5, shortest distance D between junction 167 andplane 173, containing respective rotational axes 159 of opposing rollers157, is less than a radius of a smallest one of opposing rollers 157.The preceding subject matter of this paragraph characterizes example 147of the present disclosure, wherein example 147 also includes the subjectmatter according to example 146, above.

Again, having delivery guide 112 in close proximity to opposing rollers157, such as with junction 167 within distance D of plane 173, non-resincomponent 108 operatively may be pushed into and through delivery guide112.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 4, 5, 29,and 30, junction 167 comprises an edge. The preceding subject matter ofthis paragraph characterizes example 148 of the present disclosure,wherein example 148 also includes the subject matter according to anyone of examples 146 or 147, above.

When junction 167 comprises an edge, the edge may be positioned in veryclose proximity to the interface between opposing rollers 157 and theinterface between opposing rollers 157 and non-resin component 108.

In some examples, the edge may be linear. In some examples, the edge maybe a sharp edge. In some examples, the edge may be a rounded edge.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 17-20,23, 32, and 33, delivery guide 112 further comprises outlet 206 and linepassage 154, extending from first inlet 170 to outlet 206. Outlet 206 isconfigured to provide an exit for continuous flexible line 106 fromdelivery guide 112. System 100 further comprises cutter 208, configuredto selectively cut continuous flexible line 106 adjacent to outlet 206.The preceding subject matter of this paragraph characterizes example 149of the present disclosure, wherein example 149 also includes the subjectmatter according to any one of examples 1-148, above.

Inclusion of cutter 208 permits for the selective stopping and startingof delivery of continuous flexible line 106 by delivery guide 112. Byhaving cutter 208 configured to cut continuous flexible line 106adjacent to outlet 206, continuous flexible line 106 may be cut prior tobeing cured, such as by curing energy 118, and while continuous flexibleline 106 is not yet in contact with, and optionally compacted against, aprior deposited layer of continuous flexible line 106. In other words,access to an entirety of the circumference of continuous flexible line106 by cutter 208 is permitted.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 17-19,23, 32, and 33, cutter 208 comprises at least one blade 210, movablerelative to delivery guide 112. The preceding subject matter of thisparagraph characterizes example 150 of the present disclosure, whereinexample 150 also includes the subject matter according to example 149,above.

Inclusion of at least one blade 210 may provide for a cost-effectivecutter 208.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 17, cutter208 is iris diaphragm 212. The preceding subject matter of thisparagraph characterizes example 151 of the present disclosure, whereinexample 151 also includes the subject matter according to any one ofexamples 149 or 150, above.

Iris diaphragm 212 enables cutting of continuous flexible line 106 frommultiple sides of continuous flexible line 106. Accordingly, across-sectional profile of continuous flexible line 106 may be lessdeformed by cutter 208 than may otherwise result from other examples ofcutter 208.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 17 and19, cutter 208 is positioned within delivery guide 112. The precedingsubject matter of this paragraph characterizes example 152 of thepresent disclosure, wherein example 152 also includes the subject matteraccording to any one of examples 149-151, above.

Positioning of cutter 208 within delivery guide 112 provides for acompact assembly of system 100, such that cutter 208 does not hindermovement of delivery guide 112 relative to surface 114 and/or viceversa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 20, cutter208 comprises cutting laser 213. The preceding subject matter of thisparagraph characterizes example 153 of the present disclosure, whereinexample 153 also includes the subject matter according to example 149,above.

Use of cutting laser 213 to cut continuous flexible line 106 facilitatesprecision cutting of continuous flexible line 106 at a desired locationduring manufacture of composite part 102.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 20, cutter208 further comprises at least one galvanometer mirror-positioningsystem 214, configured to direct cutting laser 213 to selectively cutcontinuous flexible line 106 adjacent to outlet 206. The precedingsubject matter of this paragraph characterizes example 154 of thepresent disclosure, wherein example 154 also includes the subject matteraccording to example 153, above.

In other words, one or more galvanometer mirror-positioning systems 214may actively direct cutting laser 213 at continuous flexible line 106 asit exits delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 22, system100 further comprises drive assembly 216, operatively coupled at leastto one of delivery guide 112 or surface 114 and configured tooperatively and selectively move at least one of delivery guide 112 orsurface 114 relative to another. The preceding subject matter of thisparagraph characterizes example 155 of the present disclosure, whereinexample 155 also includes the subject matter according to any one ofexamples 1-154, above.

Drive assembly 216 facilitates the relative movement between deliveryguide 112 and surface 114 so that composite part 102 is manufacturedfrom continuous flexible line 106 as it is deposited via delivery guide112.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 20, driveassembly 216 comprises X-axis drive 217, Y-axis drive 219, and Z-axisdrive 215, at least one of which is operatively coupled at least to oneof delivery guide 112 or surface 114. The preceding subject matter ofthis paragraph characterizes example 156 of the present disclosure,wherein example 156 also includes the subject matter according toexample 155, above.

System 100 according to example 156 provides for three-dimensionalrelative movement between delivery guide 112 and surface 114.

Referring generally to FIG. 1, drive assembly 216 comprises robotic arm218. The preceding subject matter of this paragraph characterizesexample 157 of the present disclosure, wherein example 157 also includesthe subject matter according to any one of examples 155 or 156, above.

Use of robotic arm 218 to operatively and selectively move deliveryguide 112 relative to surface 114 and/or vice versa permits for multipledegrees of freedom and the manufacture of complex three-dimensionalcomposite parts 102.

A sub-assembly of system 100 therefore may be described as anend-effector for robotic arm 218.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 22, driveassembly 216 is configured to operatively and selectively move at leastone of delivery guide 112 or surface 114 orthogonally in threedimensions relative to another. The preceding subject matter of thisparagraph characterizes example 158 of the present disclosure, whereinexample 158 also includes the subject matter according to any one ofexamples 155-157, above.

System 100 according to example 158 may manufacture composite part 102in three dimensions.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 22 and38, drive assembly 216 is configured to operatively and selectively moveat least one of delivery guide 112 or surface 114 in three dimensionswith at least three degrees of freedom relative to another. Thepreceding subject matter of this paragraph characterizes example 159 ofthe present disclosure, wherein example 159 also includes the subjectmatter according to any one of examples 155-157, above.

System 100 according to example 159 may manufacture complexthree-dimensional composite parts 102.

Referring generally to FIGS. 1 and 38, drive assembly 216 is configuredto operatively and selectively move at least one of delivery guide 112or surface 114 in three dimensions with at least six degrees of freedomrelative to another. The preceding subject matter of this paragraphcharacterizes example 160 of the present disclosure, wherein example 160also includes the subject matter according to any one of examples155-157, above.

System 100 according to example 160 may manufacture complexthree-dimensional composite parts 102.

Referring generally to FIGS. 1 and 38, drive assembly 216 is configuredto operatively and selectively move at least one of delivery guide 112or surface 114 in three dimensions with at least nine degrees of freedomrelative to another. The preceding subject matter of this paragraphcharacterizes example 161 of the present disclosure, wherein example 161also includes the subject matter according to any one of examples155-157, above.

System 100 according to example 161 may manufacture complexthree-dimensional composite parts 102.

Referring generally to FIGS. 1 and 38, drive assembly 216 is configuredto operatively and selectively move at least one of delivery guide 112or surface 114 in three dimensions with at least twelve degrees offreedom relative to another. The preceding subject matter of thisparagraph characterizes example 162 of the present disclosure, whereinexample 162 also includes the subject matter according to any one ofexamples 155-157, above.

System 100 according to example 162 may manufacture complexthree-dimensional composite parts 102.

With reference to FIG. 38, a schematic illustration according to example162 is presented, with linear translational elements 290 and rotationalelements 292 providing twelve degrees of freedom between delivery guide112 and surface 114, and with controller 294 being operativelycommunicatively coupled to linear translational elements 290 androtational elements 292.

Referring to FIG. 1, system 100 further comprises shielding-gas outlet220, configured to at least partially protect segment 120 of continuousflexible line 106 from oxidation by delivering shielding gas 221 tosegment 120 of continuous flexible line 106 after segment 120 exitsdelivery guide 112. The preceding subject matter of this paragraphcharacterizes example 163 of the present disclosure, wherein example 163also includes the subject matter according to any one of examples 1-162,above.

Inclusion of shielding-gas outlet 220 and delivery of shielding gas 221therefrom to segment 120 restricts oxidation of continuous flexible line106 prior to being further cured and/or during further curing by source116.

Referring to FIG. 1, system 100 further comprises shielding-gas source222, selectively communicatively coupled with shielding-gas outlet 220.The preceding subject matter of this paragraph characterizes example 164of the present disclosure, wherein example 164 also includes the subjectmatter according to example 163, above.

Shielding-gas source 222 provides a source of shielding gas 221 to bedelivered to segment 120 via shielding-gas outlet 220.

Referring to FIG. 1, system 100 further comprises pivoting arm 152,coupled relative to delivery guide 112 such that pivoting arm 152 trailsdelivery guide 112 as at least one of delivery guide 112 or surface 114moves relative to another. Shielding-gas outlet 220 is operativelycoupled to pivoting arm 152. The preceding subject matter of thisparagraph characterizes example 165 of the present disclosure, whereinexample 165 also includes the subject matter according to any one ofexamples 163 or 164, above.

By being coupled to pivoting arm 152, shielding-gas outlet 220 isselectively positioned to deliver shielding gas 221 to segment 120 asdelivery guide 112 moves relative to surface 114 and/or vice versa.

Referring to FIG. 1, system 100 further comprises defect detector 224,configured to detect defects in segment 120 of continuous flexible line106 after segment 120 of continuous flexible line 106 exits deliveryguide 112. The preceding subject matter of this paragraph characterizesexample 166 of the present disclosure, wherein example 166 also includesthe subject matter according to any one of examples 1-165, above.

Detection of defects in segment 120 permits for selective scrapping ofcomposite parts 102 having defects prior to completion of compositeparts 102. Accordingly, less material may be wasted. Moreover, defectsthat otherwise would be hidden from view by various types of defectdetectors may be detected by defect detector 224 prior to a subsequentlayer of continuous flexible line 106 obscuring, or hiding, the defectfrom view.

Referring to FIG. 1, defect detector 224 comprises optical detector 226or ultrasonic detector 227. The preceding subject matter of thisparagraph characterizes example 167 of the present disclosure, whereinexample 167 also includes the subject matter according to example 166,above.

In some applications, optical detector 226 may be well suited to detectdefects in segment 120 of continuous flexible line 106. In someapplications, ultrasonic detector 227 may be well suited to detectdefects in segment 120 of continuous flexible line 106.

Referring to FIG. 1, defect detector 224 comprises camera 228. Thepreceding subject matter of this paragraph characterizes example 168 ofthe present disclosure, wherein example 168 also includes the subjectmatter according to example 166, above.

Camera 228 may be well suited to detect defects in segment 120 ofcontinuous flexible line 106.

Referring to FIG. 1, system 100 further comprises controller 230 and oneor more of source 116 of curing energy 118; resin-metering system 256;at least one sensor 254; first pump 265; second pump 267; first vessel262; second vessel 272; origin 126 of non-resin component 108;pivoting-arm actuator 188; compactor 138; surface roughener 144; motor162; debris inlet 202; vacuum source 203, selectively communicativelycoupled with debris inlet 202; pressurized-gas outlet 204;pressurized-gas source 205, selectively communicatively coupled withpressurized-gas outlet 204; cutter 208; drive assembly 216;shielding-gas outlet 220; shielding-gas source 222, selectivelycommunicatively coupled with shielding-gas outlet 220; defect detector224; heat source 136; heater 602, positioned to heat continuous flexibleline 106 prior to exiting delivery guide 112; cooling system 234;delivery system 103; vacuum table 115; or surface 114. Controller 230 isprogrammed to selectively operate one or more of delivery guide 112,feed mechanism 104, source 116 of curing energy 118, resin-meteringsystem 256, at least one sensor 254, first pump 265, second pump 267,first vessel 262, second vessel 272, origin 126 of non-resin component108, pivoting-arm actuator 188, compactor 138, surface roughener 144,motor 162, vacuum source 203, pressurized-gas source 205, cutter 208,drive assembly 216, shielding-gas source 222, defect detector 224, heatsource 136, heater 602, cooling system 234, delivery system 103, vacuumtable 115, or surface 114. The preceding subject matter of thisparagraph characterizes example 169 of the present disclosure, whereinexample 169 also includes the subject matter according to any one ofexamples 1-168, above.

Controller 230 controls the operation of various component parts ofsystem 100. For example, precise movement of delivery guide 112 and/orsurface 114 relative to each other may be controlled to manufacture adesired three-dimensional composite part 102. Precise pivoting ofpivoting arm 152 by pivoting-arm actuator 188 may be controlled toprecisely deliver a compaction force by compactor 138, to preciselydeliver curing energy 118, to precisely abrade continuous flexible line106 by surface roughener 144, and so forth. Additionally, operation ofvarious component parts may be selectively started and stopped bycontroller 230 during manufacture of composite part 102 to createdesired properties and configurations of composite part 102.

In FIG. 1, communication between controller 230 and various componentparts of system 100 is schematically represented by lightning bolts.Such communication may be wired and/or wireless in nature.

Controller 230 may include any suitable structure that may be adapted,configured, designed, constructed, and/or programmed to automaticallycontrol the operation of at least a portion of system 100. Asillustrative, non-exclusive examples, controller 230 may include and/orbe an electronic controller, a dedicated controller, a special-purposecontroller, a personal computer, a display device, a logic device,and/or a memory device. In addition, controller 230 may be programmed toperform one or more algorithms to automatically control the operation ofsystem 100. This may include algorithms that may be based upon and/orthat may cause controller 230 to direct system 100 to perform methods300 and 400 disclosed herein.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 22, system100 further comprises frame 232. Frame 232 supports feed mechanism 104and surface 114. The preceding subject matter of this paragraphcharacterizes example 170 of the present disclosure, wherein example 170also includes the subject matter according to any one of examples 1-169,above.

Frame 232 structurally supports feed mechanism 104 and surface 114 sothat feed mechanism 104 may operatively and selectively move deliveryguide 112 relative to surface 114 and/or vice versa.

Referring generally to FIG. 1, thermosetting resin component 110 isconfigured to cure at a temperature between about 20° C. and about 30°C. within a period greater than 5 minutes or to cure at a temperaturegreater than about 150° C. within a period of less than 5 seconds. Thepreceding subject matter of this paragraph characterizes example 171 ofthe present disclosure, wherein example 171 also includes the subjectmatter according to any one of examples 1-170, above.

Various thermosetting resins 252 may be used for thermosetting resincomponent 110 and may be selected based on one or more of desiredproperties prior to being cured, desired properties after being fullycured, desired curing properties, such as based on length of time and/ortemperatures required to fully cure, etc. The examples set forth inexample 171 are illustrative and non-exclusive, and other configurationsof thermosetting resin 252, and thus thermosetting resin component 110,may be used with system 100. Moreover, the various temperature valuesmay vary for a particular thermosetting resin 252 and thermosettingresin component 110 based on a volume of thermosetting resin 252 presentat a location being cured.

Referring generally to FIG. 1, delivery guide 112 is configured to atleast partially cure continuous flexible line 106 prior to exitingdelivery guide 112. The preceding subject matter of this paragraphcharacterizes example 172 of the present disclosure, wherein example 172also includes the subject matter according to any one of examples 1-171,above.

In some applications, it may be desirable to initiate the curing ofcontinuous flexible line 106 prior to it being deposited.

Referring to FIG. 1, delivery guide 112 comprises heater 602, positionedto heat continuous flexible line 106 prior to exiting delivery guide112. The preceding subject matter of this paragraph characterizesexample 173 of the present disclosure, wherein example 173 also includesthe subject matter according to example 172, above.

Heater 602 may provide for efficient curing, or pre-curing, orcontinuous flexible line 106 prior to exiting delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 2 and 3,delivery guide 112 further comprises outlet 206 and line passage 154,extending from first inlet 170 to outlet 206. Outlet 206 is configuredto provide an exit for continuous flexible line 106 from delivery guide112. Heater 602 comprises resistive heater 604 positioned adjacent tooutlet 206. The preceding subject matter of this paragraph characterizesexample 174 of the present disclosure, wherein example 174 also includesthe subject matter according to example 173, above.

Resistive heater 604 may be an efficient and inexpensive option forgenerating heat for at least partially curing continuous flexible line106 prior to exiting delivery guide 112. Moreover, resistive heater 251may provide for efficient packaging of delivery guide 112 with heater602.

Referring to FIG. 1, system 100 further comprises cooling system 234,configured to maintain first part 253 of thermosetting resin 252 andsecond part 255 of thermosetting resin 252 below a threshold temperatureat least prior to first part 253 of thermosetting resin 252 and secondpart 255 of thermosetting resin 252 being received by delivery guide112. The preceding subject matter of this paragraph characterizesexample 175 of the present disclosure, wherein example 175 also includesthe subject matter according to any one of examples 1-174, above.

Cooling system 234 maintains first part 253 and second part 255 ofthermosetting resin 252 below a threshold temperature, so as to maintaindesired properties, such as viscosity of first part 253 and second part255 prior to being combined. Moreover, the threshold temperature may beselected such that even after being combined, the combined thermosettingresin 252 is restricted from curing until thermosetting resin component110 is formed and continuous flexible line 106 is deposited.

Referring generally to FIG. 1, cooling system 234 is further configuredto maintain first part 253 of thermosetting resin 252 and second part255 of thermosetting resin 252 below a threshold temperature withindelivery guide 112. The preceding subject matter of this paragraphcharacterizes example 176 of the present disclosure, wherein example 176also includes the subject matter according to example 175, above.

By maintaining first part 253 and second part 255, whether prior tobeing mixed together or after being mixed together, below a thresholdtemperature within delivery guide 112, thermosetting resin 252 andthermosetting resin component 110 may be restricted from curing withindelivery guide 112, thereby avoiding delivery guide 112 becoming cloggedor otherwise unusable.

Referring to FIG. 1, system 100 further comprises first vessel 262,configured to dispense first part 253 of thermosetting resin 252. System100 further comprises second vessel 272, configured to dispense secondpart 255 of thermosetting resin 252. Cooling system 234 comprises one ormore insulated stores 244. First vessel 262 and second vessel 272 arepositioned within insulated stores 244. The preceding subject matter ofthis paragraph characterizes example 177 of the present disclosure,wherein example 177 also includes the subject matter according to anyone of examples 175 or 176, above.

Inclusion of one or more insulated stores 244 within which first vessel262 and second vessel 272 are positioned facilitates maintaining firstpart 253 and second part 255 below a threshold temperature.

Referring to FIG. 1, cooling system 234 further comprises pump 238 andcoolant line 240, communicatively coupled with pump 238 and thermallycoupled with one or more insulated stores 244. Pump 238 is configured tocirculate coolant 246 through coolant line 240 to cool one or moreinsulated stores 244. The preceding subject matter of this paragraphcharacterizes example 178 of the present disclosure, wherein example 178also includes the subject matter according to example 177, above.

Pump 238 may be used to circulate coolant 246 through coolant line 240,which due to being thermally coupled with one or more insulated stores244, draws heat away from insulated stores 244 and further facilitatesmaintaining first part 253 and second part 255 below a thresholdtemperature.

Other mechanisms for maintaining insulated stores 244 and first part 253and second part 255 of thermosetting resin 252 below a thresholdtemperature, including mechanisms that utilize a refrigeration cycle,also are within the scope of the present disclosure.

Referring to FIG. 1, system 100 further comprises first vessel 262,configured to dispense first part 253 of thermosetting resin 252, andsecond vessel 272, configured to dispense second part 255 ofthermosetting resin 252. First vessel 262 and second vessel 272 comprisecooling system 234. The preceding subject matter of this paragraphcharacterizes example 179 of the present disclosure, wherein example 179also includes the subject matter according to any one of examples 175 or176, above.

By having first vessel 262 and second vessel 272 comprising coolingsystem 234, an efficient packaging of system 100 may be facilitated,such as avoiding one or more insulated stores 244.

Referring to FIG. 1, system 100 further comprises delivery system 103.Delivery system 103 comprises first vessel 262, configured to dispensefirst part 253 of thermosetting resin 252, second vessel 272, configuredto dispense second part 255 of thermosetting resin 252, and one or moredelivery lines 242, through which first part 253 of thermosetting resin252 and second part 255 of thermosetting resin are delivered to deliveryguide 112. System 100 further comprises cooling system 234, configuredto maintain first part 253 of thermosetting resin 252 and second part255 of thermosetting resin 252 within one or more delivery lines 242below a threshold temperature. The preceding subject matter of thisparagraph characterizes example 180 of the present disclosure, whereinexample 180 also includes the subject matter according to any one ofexamples 1-178, above.

Cooling system 234 being configured to maintain first part 253 andsecond part 255 of thermosetting resin 252 within one or more deliverylines 242 below a threshold temperature enables a desired temperature offirst part 253 and second part 255 prior to being mixed together, andthus enables a desired temperature of thermosetting resin 252 afterfirst part 253 and second part 255 have been mixed together.

Referring to FIG. 1, system 100 further comprises cooling system 234,configured to maintain thermosetting resin component 110 of continuousflexible line 106 below a threshold temperature prior to continuousflexible line 106 being deposited by delivery guide 112. The precedingsubject matter of this paragraph characterizes example 181 of thepresent disclosure, wherein example 181 also includes the subject matteraccording to any one of examples 1-180, above.

By having cooling system 234 configured to maintain thermosetting resincomponent 110, that is after thermosetting resin 252 has been applied tonon-resin component 108, below a threshold temperature, continuousflexible line 106 may be restricted from curing until it is deposited orat least just prior in time to being deposited.

Referring to FIG. 1, delivery guide 112 comprises cooling system 234.The preceding subject matter of this paragraph characterizes example 182of the present disclosure, wherein example 182 also includes the subjectmatter according to example 181, above.

When delivery guide 112 comprises cooling system 234, thermosettingresin component 110 may be restricted from being cured prior tocontinuous flexible line 106 being deposited by delivery guide 112.

Referring generally to FIG. 1, the threshold temperature is no greaterthan 20° C., 15° C., 10° C., 5° C., 0° C., −50° C., −100° C., −150° C.,−200° C., −200-−100° C., −100-0° C., −50-5° C., 5-20° C., 5-15° C., or5-10° C. The preceding subject matter of this paragraph characterizesexample 183 of the present disclosure, wherein example 183 also includesthe subject matter according to any one of examples 175-182, above.

The threshold temperature associated with system 100 and cooling system234 may be selected based on thermosetting resin 252 being used forthermosetting resin component 110, and the examples set forth in example183 are illustrative and non-exclusive. Moreover, the thresholdtemperature may be selected to prevent curing of thermosetting resin 252and thus thermosetting resin component 110 prior to being deposited.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 22, system100 further comprises surface 114. The preceding subject matter of thisparagraph characterizes example 184 of the present disclosure, whereinexample 184 also includes the subject matter according to any one ofexamples 1-183, above.

Inclusion of surface 114 as part of system 100 provides for selectiveproperties and characteristics of surface 114.

Referring generally to FIG. 1, surface 114 is configured to beselectively heated. The preceding subject matter of this paragraphcharacterizes example 185 of the present disclosure, wherein example 185also includes the subject matter according to example 184, above.

Selective heating of surface 114 may facilitate curing of an initiallayer of continuous flexible line 106 being deposited. Additionally oralternatively, selective heating of surface 114, such as at or near thecompletion of composite part 102, may facilitate removal of compositepart 102 from surface 114.

Referring to FIG. 1, surface 114 comprises vacuum table 115. Thepreceding subject matter of this paragraph characterizes example 186 ofthe present disclosure, wherein example 186 also includes the subjectmatter according to any one of examples 184 or 185, above.

Vacuum table 115 may help to secure composite part 102 to surface 114while composite part 102 is being manufacture by system 100.

Referring generally to FIG. 1, delivery guide 112 further comprisesoutlet 206 configured to provide an exit for continuous flexible line106 from delivery guide 112. Outlet 206 is further configured to imparta predetermined texture to continuous flexible line 106 as it exitsdelivery guide 112. The preceding subject matter of this paragraphcharacterizes example 187 of the present disclosure, wherein example 187also includes the subject matter according to any one of examples 1-186,above.

By imparting a texture to continuous flexible line at outlet 206 ofdelivery guide 112, a desired adhesion between layers of continuousflexible line being deposited may be achieved. Moreover, in comparisonto other examples disclosed herein, a more efficient packaging of system100 may be achieved, while still providing the desired functionality ofapplying texture to continuous flexible line 106.

Referring, e.g., to FIGS. 1, 8-11, 14, 21, and 23-28 and particularly toFIG. 34, method 300 of additively manufacturing composite part 102 isdisclosed. Method 300 comprises (block 302) depositing segment 120 ofcontinuous flexible line 106 along print path 122. Continuous flexibleline 106 comprises non-resin component 108 and thermosetting resincomponent 110 that is not fully cured. Method 300 further comprises(block 304), while advancing continuous flexible line 106 toward printpath 122, delivering a predetermined or actively determined amount ofcuring energy 118 at least to portion 124 of segment 120 of continuousflexible line 106 at a controlled rate after segment 120 of continuousflexible line 106 is deposited along print path 122 to at leastpartially cure at least portion 124 of segment 120 of continuousflexible line 106. The preceding subject matter of this paragraphcharacterizes example 188 of the present disclosure.

Method 300 therefore may be performed to manufacture composite parts 102from at least a composite material that includes thermosetting resincomponent 110 initially in an uncured state and that is at leastpartially cured while composite part 102 is being manufactured, or insitu, by curing energy 118. As a result of delivering a predetermined oractively determined amount of curing energy 118 at a controlled rate, adesired level, or degree, of cure may be established with respect toportion 124 of segment 120 at any given time during manufacture ofcomposite part 102. For example, as discussed herein, in some examples,it may be desirable to cure one portion 124 greater than or less thananother portion 124 during manufacture of composite part 102. Moreover,method 300 may be performed to manufacture composite parts 102 withcontinuous flexible line 106 being oriented in desired and/orpredetermined orientations throughout composite part 102, such as todefine desired properties of composite part 102.

Method 300 may be performed by system 100.

Referring, e.g., to FIGS. 1-5 and particularly to FIG. 34, method 300further comprises (block 306) applying thermosetting resin 252 tonon-resin component 108 while pushing continuous flexible line 106 outof delivery guide 112. Thermosetting resin component 110 comprises atleast some of thermosetting resin 252 applied to non-resin component108. The preceding subject matter of this paragraph characterizesexample 189 of the present disclosure, wherein example 189 also includesthe subject matter according to example 188, above.

By applying thermosetting resin 252 to non-resin component 108 duringthe manufacture of composite part 102, continuous flexible line 106 iscreated during manufacture of composite part 102. Accordingly, differentnon-resin components 108 and/or different thermosetting resins 252 maybe selected during performance of method 300 to customize or otherwisecreate a desired composite part 102 with different characteristics atdifferent locations within composite part 102. Moreover, depending onthe properties of thermosetting resin 252 and/or its component parts, acomplex and/or expensive cooling system may not be required to restrictcuring of thermosetting resin 252 prior to thermosetting resin component110 being applied to non-resin component 108 and continuous flexibleline 108 being deposited.

Referring, e.g., to FIGS. 1-5 and particularly to FIG. 34, according tomethod 300, (block 306) applying thermosetting resin 252 to non-resincomponent 108 while pushing continuous flexible line 106 out of deliveryguide 112 comprises (block 308) injecting thermosetting resin 252 intodelivery guide 112. The preceding subject matter of this paragraphcharacterizes example 190 of the present disclosure, wherein example 190also includes the subject matter according to example 189, above.

Injecting thermosetting resin 252 into delivery guide 112, as opposedto, e.g., pulling non-resin component 108 through a resin bath, permitsfor precise control of the application of thermosetting resin 252 tonon-resin component 108.

Referring, e.g., to FIGS. 1-3 and 5 and particularly to FIG. 34,according to method 300, (block 308) injecting thermosetting resin 252into delivery guide 112 comprises (block 310) separately injecting firstpart 253 of thermosetting resin 252 and second part 255 of thermosettingresin 252 into delivery guide 112. The preceding subject matter of thisparagraph characterizes example 191 of the present disclosure, whereinexample 191 also includes the subject matter according to example 190,above.

By separately injecting first part 253 and second part 255 into deliveryguide 112, and thus, e.g., closer to outlet 206 of delivery guide 112,the amount of time that first part 253 and second part 255 areintermixed prior to being deposited as part of thermosetting resincomponent 110 may be minimized. As a result, curing of thermosettingresin component 110 and continuous flexible line 106 may be restricteduntil continuous flexible line 106 is deposited by delivery guide 112.

Referring, e.g., to FIGS. 1-3 and 5 and particularly to FIG. 34, method300 further comprises (block 312) mixing first part 253 of thermosettingresin 252 and second part 255 of thermosetting resin 252 within deliveryguide 112. The preceding subject matter of this paragraph characterizesexample 192 of the present disclosure, wherein example 192 also includesthe subject matter according to example 191, above.

By mixing first part 253 and second part 255 within delivery guide 112,the amount of time that first part 253 and second part 255 areintermixed prior to being deposited as part of thermosetting resincomponent 110 may be minimized. As a result, curing of thermosettingresin component 110 and continuous flexible line 106 may be restricteduntil continuous flexible line 106 is deposited by delivery guide 112.

Referring, e.g., to FIGS. 1 and 4 and particularly to FIG. 34, method300 further comprises (block 314) mixing first part 253 of thermosettingresin 252 and second part 255 of thermosetting resin 252 externally todelivery guide 112. The preceding subject matter of this paragraphcharacterizes example 193 of the present disclosure, wherein example 193also includes the subject matter according to example 190, above.

Mixing first part 253 and second part 255 externally to delivery guide112 may provide for a less complex delivery guide structure and moreefficient packaging of delivery guide 112. Moreover, as discussedherein, such a configuration may facilitate use of off-the-shelf resinmixers that may be easily and inexpensively replaced, when needed.

Referring, e.g., to FIGS. 1, 4, and 5 and particularly to FIG. 34,according to method 300, (block 306) applying thermosetting resin 252 tonon-resin component 108 while pushing continuous flexible line 106 outof delivery guide 112 comprises (block 316) metering a flow ofthermosetting resin 252. The preceding subject matter of this paragraphcharacterizes example 194 of the present disclosure, wherein example 194also includes the subject matter according to any one of examples189-193, above.

Metering the flow of thermosetting resin 252 permits for the selectiveincrease and the selective decrease of the volume of thermosetting resin252 applied to non-resin component 108. Accordingly, a desired level ofsaturation of non-resin component 108 with thermosetting resin 252 maybe achieved.

Referring, e.g., to FIGS. 1, 4, and 5 and particularly to FIG. 34,according to method 300, (block 316) metering the flow of thermosettingresin 252 comprises (block 318) detecting a level of thermosetting resin252 within delivery guide 112. The preceding subject matter of thisparagraph characterizes example 195 of the present disclosure, whereinexample 195 also includes the subject matter according to example 194,above.

Detection of a level of thermosetting resin 252 within delivery guide112 provides a data input for metering the flow of thermosetting resin252 to non-resin component 108.

Referring, e.g., to FIGS. 1, 4, and 5 and particularly to FIG. 34,according to method 300, (block 316) metering the flow of thermosettingresin 252 comprises (block 320) selectively reducing or selectivelyincreasing the flow of thermosetting resin 252 to delivery guide 112responsive to the level of thermosetting resin 252 within delivery guide112. The preceding subject matter of this paragraph characterizesexample 196 of the present disclosure, wherein example 196 also includesthe subject matter according to example 195, above.

The selective reduction of the flow of thermosetting resin 252 permitsfor avoidance of overflowing thermosetting resin 252 from delivery guide112. The selective increase of the flow of thermosetting resin 252permits for avoidance of an undesirably low level of saturation ofnon-resin component 108 with thermosetting resin 252.

Referring, e.g., to FIGS. 1, 4, and 5 and particularly to FIG. 34,according to method 300, (block 316) metering the flow of thermosettingresin 252 comprises (block 322) detecting a saturation level ofnon-resin component 108 with thermosetting resin 252. The precedingsubject matter of this paragraph characterizes example 197 of thepresent disclosure, wherein example 197 also includes the subject matteraccording to any one of examples 194-196, above.

Detecting a saturation level of non-resin component 108 withthermosetting resin 252, as opposed to, e.g., simply detecting thepresence of thermosetting resin 252 at a given position, may facilitateprecisely ensuring a desired level of saturation, such as ensuringadequate penetration of non-resin component 108 with thermosetting resin252.

Referring, e.g., to FIGS. 1, 4, and 5 and particularly to FIG. 34,according to method 300, (block 316) metering the flow of thermosettingresin 252 comprises (block 324) selectively reducing or selectivelyincreasing the flow of thermosetting resin 252 to delivery guide 112responsive to the saturation level of non-resin component 108 withthermosetting resin 252. The preceding subject matter of this paragraphcharacterizes example 198 of the present disclosure, wherein example 198also includes the subject matter according to example 197, above.

The selective reduction and the selective increase of the flow ofthermosetting resin 252 responsive to the saturation level facilitateprecisely achieving a desired level of saturation of non-resin component108 with thermosetting resin 252.

Referring, e.g., to FIGS. 1, 4, and 5 and particularly to FIG. 34,according to method 300, (block 316) metering the flow of thermosettingresin 252 comprises (block 326) metering a flow of first part 253 ofthermosetting resin 252 and metering a flow of second part 255 ofthermosetting resin 252. The preceding subject matter of this paragraphcharacterizes example 199 of the present disclosure, wherein example 199also includes the subject matter according to any one of examples194-198, above.

Metering the flow of first part 253 and second part 255, that is beforethey are mixed to create thermosetting resin 252, permits for separatelyincreasing and decreasing the flow of first part 253 and second part255. Accordingly, while composite part 102 is being manufactured, theratio of first part 253 to second part 255 may be actively varied, suchas to result in desired properties of continuous flexible line 106 alongits length and to result in varied properties at different locationswithin composite part 102.

Referring, e.g., to FIG. 1 and particularly to FIG. 34, method 300further comprises (block 386) maintaining thermosetting resin 252 belowa threshold temperature at least prior to applying thermosetting resin252 to non-resin component 108. The preceding subject matter of thisparagraph characterizes example 200 of the present disclosure, whereinexample 200 also includes the subject matter according to any one ofexamples 189-199, above.

Maintaining thermosetting resin 252 below a threshold temperature priorto being applied to non-resin component 108 restricts curing ofthermosetting resin component 110 before continuous flexible line 106 isdeposited.

Referring, e.g., to FIG. 1 and particularly to FIG. 34, method 300further comprises (block 388) maintaining thermosetting resin component110 below a threshold temperature prior to depositing segment 120 ofcontinuous flexible line 106 along print path 122. The preceding subjectmatter of this paragraph characterizes example 201 of the presentdisclosure, wherein example 201 also includes the subject matteraccording to any one of examples 189-200, above.

Maintaining thermosetting resin component 110 below a thresholdtemperature prior to continuous flexible line 106 being depositedrestricts curing of thermosetting resin component 110.

Referring to FIG. 34, according to method 300, (block 390) the thresholdtemperature is no greater than 20° C., 15° C., 10° C., 5° C., 0° C.,−50° C., −100° C., −150° C., −200° C., −200-−100° C., −100-0° C., −50-5°C., 5-20° C., 5-15° C., or 5-10° C. The preceding subject matter of thisparagraph characterizes example 202 of the present disclosure, whereinexample 202 also includes the subject matter according to any one ofexamples 200 or 201, above.

The threshold temperature associated with method 300 may be selectedbased on a thermosetting resin 252 being used, and the examples setforth in example 202 are illustrative and non-exclusive.

Referring, e.g., to FIGS. 6 and 7 and particularly to FIG. 34, accordingto method 300, (block 328) non-resin component 108 comprises one or moreof a fiber, a carbon fiber, a glass fiber, a synthetic organic fiber, anaramid fiber, a natural fiber, a wood fiber, a boron fiber, asilicon-carbide fiber, an optical fiber, a fiber bundle, a fiber tow, afiber weave, a wire, a metal wire, a conductive wire, or a wire bundle.The preceding subject matter of this paragraph characterizes example 203of the present disclosure, wherein example 203 also includes the subjectmatter according to any one of examples 188-202, above.

Inclusion of a fiber or fibers in continuous flexible line 106 permitsfor selecting desired properties of composite part 102. Moreover,selection of specific materials of fibers and/or selection of specificconfigurations of fibers (e.g., a bundle, a tow, and/or a weave) maypermit for precise selection of desired properties of composite part102. Example properties of composite parts 102 include strength,stiffness, flexibility, ductility, hardness, electrical conductivity,thermal conductivity, etc. Non-resin component 108 is not limited to theidentified examples, and other types of non-resin component 108 may beused.

FIG. 6 schematically represents continuous flexible line 106 with asingle fiber as non-resin component 108 within a matrix of thermosettingresin component 110. FIG. 7 schematically represents continuous flexibleline 106 with more than one fiber as non-resin component 108 within amatrix of thermosetting resin component 110.

Referring, e.g., to FIGS. 1 and 8 and particularly to FIG. 34, accordingto method 300, (block 302) depositing segment 120 of continuous flexibleline 106 along print path 122 comprises (block 330) layering continuousflexible line 106 against itself to additively manufacture compositepart 102. The preceding subject matter of this paragraph characterizesexample 204 of the present disclosure, wherein example 204 also includesthe subject matter according to any one of examples 188-203, above.

By layering continuous flexible line 106 against itself or a previouslydeposited segment 120, a three-dimensional composite part 102 may bemanufactured by performance of method 300.

Accordingly, method 300 may be described as a 3-D printing method and/oras an additive manufacturing method.

Referring, e.g., to FIG. 1 and particularly to FIG. 34, according tomethod 300, (block 302) depositing segment 120 of continuous flexibleline 106 along print path 122 comprises (block 332) depositingcontinuous flexible line 106 in a predetermined pattern to selectivelycontrol one or more physical characteristics of composite part 102. Thepreceding subject matter of this paragraph characterizes example 205 ofthe present disclosure, wherein example 205 also includes the subjectmatter according to any one of examples 188-204, above.

By controlling one or more physical characteristics of composite part102, less overall material may be used and/or the size of a specificcomposite part may be reduced when compared to a similar partmanufactured by a traditional composite layup method.

For example, in contrast to composite parts constructed from multiplelayers of planar plies of composite material, composite part 102 may bemanufactured so that the orientation of continuous flexible line 106,and thus of non-resin component 108, results in desired properties. Asan example, if a part includes holes, continuous flexible line 106 maybe arranged generally in concentric circles or spiral around the holes,resulting in no or few interruptions to continuous flexible line 106 atthe boundary of the holes. As a result, the strength of the compositepart may be significantly greater around the hole than a similar partconstructed by traditional composite layup methods. In addition thecomposite part may be less subject to cracks and propagation thereof atthe boundary of the holes. Moreover, because of the desired propertiesaround the holes, the overall thickness, volume, and/or mass of thecomposite part may be reduced while achieving the desired properties,when compared to a similar part constructed by traditional compositelayup methods.

Referring, e.g., to FIG. 1 and particularly to FIG. 34, according tomethod 300, (block 334) at least one of depositing segment 120 ofcontinuous flexible line 106 along print path 122 or delivering thepredetermined or actively determined amount of curing energy 118 atleast to portion 124 of segment 120 of continuous flexible line 106 atthe controlled rate provides different physical characteristics atdifferent locations of composite part 102. The preceding subject matterof this paragraph characterizes example 206 of the present disclosure,wherein example 206 also includes the subject matter according to anyone of examples 188-205, above.

Again, for various reasons and applications, it may be desirable tomanufacture composite part 102 with different properties at differentlocations.

Referring to FIG. 34, according to method 300, (blocks 336 and 338) thephysical characteristics include at least one of strength, stiffness,flexibility, ductility, or hardness. The preceding subject matter ofthis paragraph characterizes example 207 of the present disclosure,wherein example 207 also includes the subject matter according to anyone of examples 205 or 206, above.

Each of these physical characteristics may be selected for a particularpurpose. For example, in a composite part that when in use receives asignificant torque on a sub-part thereof compared to the remainder ofthe composite part, it may be desirable to have such sub-part less stiffand/or more flexible than other portions of the composite part.Additionally, it may be desirable to build more strength into a sub-partthan other portions of composite part 102 for various reasons dependingon a specific application of composite part 102.

Referring, e.g., to FIGS. 1 and 8 and particularly to FIG. 34, accordingto method 300, (block 304) delivering the predetermined or activelydetermined amount of curing energy 118 at least to portion 124 ofsegment 120 of continuous flexible line 106 at the controlled ratecomprises (block 340) partially curing first layer 140 of segment 120 ofcontinuous flexible line 106 as first layer 140 is being deposited andfurther curing first layer 140 as second layer 142 is being depositedagainst first layer 140. The preceding subject matter of this paragraphcharacterizes example 208 of the present disclosure, wherein example 208also includes the subject matter according to any one of examples188-207, above.

By only partially curing first layer 140 as first layer 140 is beingdeposited, first layer 140 may remain tacky, or sticky, therebyfacilitating adhesion of second layer 142 against first layer 140 assecond layer 142 is deposited against first layer 140. Then, first layer140 is further cured as second layer 142 is being partially cured fordeposition of a subsequent layer against second layer 142, and so forth.

Referring, e.g., to FIGS. 1 and 8 and particularly to FIG. 34, accordingto method 300, (block 304) delivering the predetermined or activelydetermined amount of curing energy 118 at least to portion 124 ofsegment 120 of continuous flexible line 106 at the controlled ratecomprises (block 342) partially curing first layer 140 of segment 120 ofcontinuous flexible line 106 as first layer 140 is being deposited andfully curing first layer 140 as second layer 142 is being depositedagainst first layer 140. The preceding subject matter of this paragraphcharacterizes example 209 of the present disclosure, wherein example 209also includes the subject matter according to any one of examples188-208, above.

Again, by only partially curing first layer 140 as first layer 140 isbeing deposited, first layer 140 may remain tacky, or sticky, therebyfacilitating adhesion of second layer 142 against first layer 140 assecond layer 142 is deposited against first layer 140. However,according to this example 209, first layer 140 is fully cured as secondlayer 142 is being partially cured.

Referring, e.g., to FIG. 1 and particularly to FIG. 34, according tomethod 300, (block 304) delivering the predetermined or activelydetermined amount of curing energy 118 at least to portion 124 ofsegment 120 of continuous flexible line 106 at the controlled ratecomprises (block 344) curing less than an entirety of composite part102. The preceding subject matter of this paragraph characterizesexample 210 of the present disclosure, wherein example 210 also includesthe subject matter according to any one of examples 188-209, above.

In some applications, a less cured portion may be desirable so that itmay be subsequently worked on by a subsequent process, such as to removematerial and/or add a structural or other component to composite part102.

Referring, e.g., to FIG. 1 and particularly to FIG. 34, method 300further comprises (block 346) restrictively curing at least a portion ofcomposite part 102. The preceding subject matter of this paragraphcharacterizes example 211 of the present disclosure, wherein example 211also includes the subject matter according to any one of examples188-210, above.

Again, in some applications, a less cured portion may be desirable sothat it may be subsequently worked on by a subsequent process, such asto remove material and/or add a structural or other component tocomposite part 102, and a less cured portion may result from restrictionof the curing process.

Referring, e.g., to FIG. 1 and particularly to FIG. 34, according tomethod 300, (block 348) the portion of composite part 102 isrestrictively cured to facilitate subsequent processing of the portion.The preceding subject matter of this paragraph characterizes example 212of the present disclosure, wherein example 212 also includes the subjectmatter according to example 211, above.

Subsequent processing on composite part 102 may be desirable, such as toremove material and/or add a structural or other component to compositepart 102.

Referring, e.g., to FIG. 1 and particularly to FIG. 34, according tomethod 300, (block 304) delivering the predetermined or activelydetermined amount of curing energy 118 at least to portion 124 ofsegment 120 of continuous flexible line 106 at the controlled ratecomprises (block 350) selectively varying at least one of a deliveryrate or a delivery duration of curing energy 118 to impart varyingphysical characteristics to composite part 102. The preceding subjectmatter of this paragraph characterizes example 213 of the presentdisclosure, wherein example 213 also includes the subject matteraccording to any one of examples 188-212, above.

By imparting varying physical characteristics to composite part 102, acustomized composite part 102 may be manufactured with sub-parts havingdesirable properties that are different from other sub-parts.

Referring to FIG. 34, according to method 300, (block 352) the varyingphysical characteristics include at least one of strength, stiffness,flexibility, ductility, or hardness. The preceding subject matter ofthis paragraph characterizes example 214 of the present disclosure,wherein example 214 also includes the subject matter according toexample 213, above.

Each of these physical characteristics may be selected for a particularpurpose. For example, in composite part 102 that when in use receives asignificant torque on a sub-part thereof compared to the remainder ofcomposite part 102, it may be desirable to have such sub-part less stiffand/or more flexible than other portions of composite part 102.Additionally, it may be desirable to build more strength into a sub-partthan other portions of composite part 102 for various reasons dependingon a specific application of composite part 102.

Referring, e.g., to FIGS. 1, 12-16, 23, and 25 and particularly to FIG.34, method 300 further comprises (block 354), simultaneously withdepositing segment 120 of continuous flexible line 106 along print path122, compacting at least section 180 of segment 120 of continuousflexible line 106 after segment 120 of continuous flexible line 106 isdeposited along print path 122. The preceding subject matter of thisparagraph characterizes example 215 of the present disclosure, whereinexample 215 also includes the subject matter according to any one ofexamples 188-214, above.

Compaction of section 180 of continuous flexible line 106 duringperformance of method 300 facilitates adherence between adjacent layersof continuous flexible line 106 being deposited during performance ofmethod 300.

Referring, e.g., to FIG. 13 and particularly to FIG. 34, according tomethod 300, (block 354) compacting at least section 180 of segment 120of continuous flexible line 106 after segment 120 of continuous flexibleline 106 is deposited along print path 122 comprises (block 356)imparting a desired cross-sectional shape to segment 120 of continuousflexible line 106. The preceding subject matter of this paragraphcharacterizes example 216 of the present disclosure, wherein example 216also includes the subject matter according to example 215, above.

It may be desirable, in some applications, to impart a predeterminedcross-sectional shape to continuous flexible line 106 as it is beingdeposited.

Referring, e.g., to FIGS. 1, 12-16, 23, and 25 and particularly to FIG.34, according to method 300, (block 354) compacting at least section 180of segment 120 of continuous flexible line 106 after segment 120 ofcontinuous flexible line 106 is deposited along print path 122 comprises(block 392) heating section 180 of segment 120 of continuous flexibleline 106 to at least partially cure at least section 180 of segment 120of continuous flexible line 106. The preceding subject matter of thisparagraph characterizes example 217 of the present disclosure, whereinexample 217 also includes the subject matter according to any one ofexamples 215 or 216, above.

Having compaction also deliver heat to continuous flexible line 106efficiently cures continuous flexible line 106.

Referring, e.g., to FIGS. 1, 12, and 23 and particularly to FIG. 34,method 300 further comprises (block 358), simultaneously with depositingsegment 120 of continuous flexible line 106 along print path 122,roughening at least section 194 of segment 120 of continuous flexibleline 106 after segment 120 of continuous flexible line 106 is depositedalong print path 122. The preceding subject matter of this paragraphcharacterizes example 218 of the present disclosure, wherein example 218also includes the subject matter according to any one of examples188-217, above.

Roughening section 194 of continuous flexible line 106 increases thesurface area thereof and aids in adhesion of a subsequent layer ofcontinuous flexible line 106 deposited against it during performance ofmethod 300.

Referring, e.g., to FIGS. 1 and 23 and particularly to FIG. 34, method300 further comprises (block 360), simultaneously with roughening atleast section 194 of segment 120 of continuous flexible line 106,collecting debris resulting from roughening at least section 194 ofsegment 120 of continuous flexible line 106. The preceding subjectmatter of this paragraph characterizes example 219 of the presentdisclosure, wherein example 219 also includes the subject matteraccording to example 218, above.

Collection of debris that results from roughening section 194 avoidsunwanted, loose particles of thermosetting resin component 110 becomingtrapped between adjacent deposited layers of continuous flexible line106 that may otherwise result in unwanted properties of composite part102.

Referring, e.g., to FIGS. 1 and 23 and particularly to FIG. 34, method300 further comprises (block 362), simultaneously with roughening atleast section 194 of segment 120 of continuous flexible line 106,dispersing debris resulting from roughening at least section 194 ofsegment 120 of continuous flexible line 106. The preceding subjectmatter of this paragraph characterizes example 220 of the presentdisclosure, wherein example 220 also includes the subject matteraccording to any one of examples 218 or 219, above.

Dispersal of debris that results from roughening section 194 avoidsunwanted, loose particles of thermosetting resin component 110 becomingtrapped between adjacent deposited layers of continuous flexible line106 that may otherwise result in unwanted properties of composite part102.

Referring, e.g., to FIGS. 1 and 23 and particularly to FIG. 34,according to method 300, (block 358) roughening at least section 194 ofsegment 120 of continuous flexible line 106 after segment 120 ofcontinuous flexible line 106 is deposited along print path 122 comprises(block 394) heating section 194 of segment 120 of continuous flexibleline 106 to at least partially cure at least section 194 of segment 120of continuous flexible line 106. The preceding subject matter of thisparagraph characterizes example 221 of the present disclosure, whereinexample 221 also includes the subject matter according to any one ofexamples 218-220, above.

Having the roughening also deliver heat to continuous flexible line 106efficiently cures continuous flexible line 106.

Referring, e.g., to FIGS. 1, 17-20, 23, 32, and 33 and particularly toFIG. 34, method 300 further comprises (block 364) selectively cuttingcontinuous flexible line 106. The preceding subject matter of thisparagraph characterizes example 222 of the present disclosure, whereinexample 222 also includes the subject matter according to any one ofexamples 188-221, above.

Selective cutting of continuous flexible line 106 during performance ofmethod 300 permits for the stopping and starting of continuous flexibleline 106 in different locations on composite part 102.

Referring, e.g., to FIGS. 1, 17-20, 23, 32, and 33 and particularly toFIG. 34, according to method 300, (block 366) continuous flexible line106 is selectively cut simultaneously with depositing segment 120 ofcontinuous flexible line 106 along print path 122. The preceding subjectmatter of this paragraph characterizes example 223 of the presentdisclosure, wherein example 223 also includes the subject matteraccording to example 222, above.

Simultaneous cutting and delivering of continuous flexible line 106provides for controlled deposition of continuous flexible line 106 alongprint path 122.

Referring, e.g., to FIG. 1 and particularly to FIG. 34, method 300further comprises (block 368), simultaneously with delivering thepredetermined or actively determined amount of curing energy 118 atleast to portion 124 of segment 120 of continuous flexible line 106 atthe controlled rate, at least partially protecting at least portion 124of segment 120 of continuous flexible line 106 from oxidation aftersegment 120 exits delivery guide 112. The preceding subject matter ofthis paragraph characterizes example 224 of the present disclosure,wherein example 224 also includes the subject matter according to anyone of examples 188-223, above.

Protecting portion 124 from oxidation may facilitate the subsequentand/or simultaneous curing of portion 124.

Referring, e.g., to FIG. 1 and particularly to FIG. 34, according tomethod 300, (block 370) at least portion 124 of segment 120 ofcontinuous flexible line 106 is at least partially protected from theoxidation with shielding gas 221. The preceding subject matter of thisparagraph characterizes example 225 of the present disclosure, whereinexample 225 also includes the subject matter according to example 224,above.

Again, protecting portion 124 from oxidation may facilitate thesubsequent and/or simultaneous curing of portion 124.

Referring, e.g., to FIG. 1 and particularly to FIG. 34, method 300further comprises (block 372), simultaneously with depositing segment120 of continuous flexible line 106 along print path 122, detectingdefects in composite part 102. The preceding subject matter of thisparagraph characterizes example 226 of the present disclosure, whereinexample 226 also includes the subject matter according to any one ofexamples 188-225, above.

Detection of defects in segment 120 permits for selective scrapping ofcomposite parts 102 having defects prior to completion of compositeparts 102. Accordingly, less material may be wasted. Moreover, defectsthat otherwise would be hidden from view by various types of defectdetectors may be detected prior to a subsequent layer of continuousflexible line 106 obscuring, or hiding, the defect from view.

Referring, e.g., to FIG. 1 and particularly to FIG. 34, according tomethod 300, (block 302) depositing segment 120 of continuous flexibleline 106 along print path 122 comprises (block 374) depositing at leasta portion of segment 120 of continuous flexible line 106 over asacrificial layer. The preceding subject matter of this paragraphcharacterizes example 227 of the present disclosure, wherein example 227also includes the subject matter according to any one of examples188-226, above.

Use of a sacrificial layer may permit for deposition of an initial layerof continuous flexible line 106 in midair without requiring an outermold, surface 114, or other rigid structure for initial deposition ofthe initial layer. That is, the sacrificial layer may become an outermold for subsequent deposition of layers that are not sacrificial.Additionally or alternatively, the sacrificial layer may be depositedwithin an internal volume of composite part 102, such as to facilitatethe formation of a void within composite part 102, with the sacrificiallayer remaining within the void or with the sacrificial layersubsequently being removed or otherwise disintegrated, for example, sothat it does not impact the structural integrity of composite part 102.

Referring, e.g., to FIG. 1 and particularly to FIG. 34, method 300further comprises (block 376) removing the sacrificial layer to formcomposite part 102. The preceding subject matter of this paragraphcharacterizes example 228 of the present disclosure, wherein example 228also includes the subject matter according to example 227, above.

Removal of the sacrificial layer results in composite part 102 being ina desired state, which may be a completed state or may be a state thatis subsequently operated on by processes after completion of method 300.

Referring, e.g., to FIG. 1 and particularly to FIG. 34, method 300further comprises (block 378) depositing segment 120A of continuousflexible line 106A along print path 122. The preceding subject matter ofthis paragraph characterizes example 229 of the present disclosure,wherein example 229 also includes the subject matter according to anyone of examples 188-228, above.

In other words, different configurations of continuous flexible line 106may be used during performance of method 300.

For example, different properties of different continuous flexible lines106 may be selected for different sub-parts of composite part 102. As anexample, continuous flexible line 106 may comprise non-resin component108 that comprises carbon fiber for a significant portion of compositepart 102, but continuous flexible line 106 may comprise non-resincomponent 108 that comprises copper wiring for another portion to definean integral electrical path for connection to an electrical component.Additionally or alternatively, a different non-resin component 108 maybe selected for an outer surface of composite part 102 than non-resincomponent 108 selected for internal portions of composite part 102.Various other examples also are within the scope of example 229.

Referring to FIG. 34, according to method 300, (block 380) continuousflexible line 106A differs from continuous flexible line 106 in at leastone of non-resin component 108 or thermosetting resin component 110. Thepreceding subject matter of this paragraph characterizes example 230 ofthe present disclosure, wherein example 230 also includes the subjectmatter according to example 229, above.

Varying non-resin component 108 and/or thermosetting resin component 110during performance of method 300 permits for customized composite parts102 to be manufactured with varying and desired properties throughoutcomposite part 102.

Referring, e.g., to FIGS. 1, 4, 5, and 29-31 and particularly to FIG.34, according to method 300, (block 302) depositing segment 120 ofcontinuous flexible line 106 along print path 122 comprises (block 382)pushing continuous flexible line 106 through delivery guide 112. Thepreceding subject matter of this paragraph characterizes example 231 ofthe present disclosure, wherein example 231 also includes the subjectmatter according to any one of examples 188-230, above.

By pushing continuous flexible line 106 through delivery guide 112,delivery guide 112 may be positioned downstream of the source of motiveforce that pushes continuous flexible line 106, such as feed mechanism104 herein. As a result, such source of motive force does not interferewith deposition of continuous flexible line 106, and delivery guide 112may be more easily manipulated in complex three-dimensional patternsduring performance of method 300.

Referring to FIG. 34, method 300 further comprises (block 384) curingcomposite part 102 in an autoclave or in an oven. The preceding subjectmatter of this paragraph characterizes example 232 of the presentdisclosure, wherein example 232 also includes the subject matteraccording to any one of examples 188-231, above.

In some applications, it may be desirable to not fully cure compositepart, in situ, that is, when continuous flexible line 106 is beingdeposited to form composite part 102. For example, as discussed, in someapplications, it may be desirable to not fully cure composite part, insitu, to permit for subsequent work on composite part 102. In suchapplications, following the subsequent work, a full cure may be achievedin an autoclave or oven.

Referring, e.g., to FIG. 1 and particularly to FIG. 34, according tomethod 300, (block 396) depositing segment 120 of continuous flexibleline 106 along print path 122 and delivering the predetermined oractively determined amount of curing energy 118 at least to portion 124of segment 120 of continuous flexible line 106 at the controlled rateare performed within chamber 258 that is one of positively pressurizedor negatively pressurized relative to atmospheric pressure. Thepreceding subject matter of this paragraph characterizes example 233 ofthe present disclosure, wherein example 233 also includes the subjectmatter according to any one of examples 188-232, above.

Depending on the configuration of composite part 102 being manufactured,it may be desirable to increase and/or decrease the pressure withinchamber 258 during curing to obtain desirable properties of compositepart 102.

Chamber 258 may be described as, or as comprising or as being comprisedby, an autoclave.

Referring, e.g., to FIG. 1 and particularly to FIG. 34, according tomethod 300, (block 302) depositing segment 120 of continuous flexibleline 106 along print path 122 comprises (block 398) initially depositingsegment 120 of continuous flexible line 106 against surface 114. Thepreceding subject matter of this paragraph characterizes example 234 ofthe present disclosure, wherein example 234 also includes the subjectmatter according to any one of examples 188-233, above.

Surface 114 therefore provides at least an initial deposition surface,against which continuous flexible line 106 may be deposited. However,subsequent layers of continuous flexible line 106 may be depositedagainst previously deposited layers of continuous flexible line 106,with surface 114 ultimately providing the structural support forcomposite part 102 and optionally compaction thereof.

Referring, e.g., to FIG. 1 and particularly to FIG. 34, method 300further comprises (block 399) heating surface 114. The preceding subjectmatter of this paragraph characterizes example 235 of the presentdisclosure, wherein example 235 also includes the subject matteraccording to example 234, above.

Selective heating of surface 114 may facilitate curing of an initiallayer of continuous flexible line 106 being deposited. Additionally oralternatively, selective heating of surface 114, such as at or near thecompletion of composite part 102, may facilitate removal of compositepart 102 from surface 114.

Referring, e.g., to FIG. 1 and particularly to FIG. 34, method 300further comprises (block 301) applying a vacuum to surface 114. Thepreceding subject matter of this paragraph characterizes example 236 ofthe present disclosure, wherein example 236 also includes the subjectmatter according to any one of examples 234 or 235, above.

Applying a vacuum to surface 114 secures composite part 102 to surface114 while composite part 102 is being manufactured by method 300.

Referring, e.g., to FIG. 1 and particularly to FIG. 34, according tomethod 300, (block 303) surface 114 comprises removable gasket 105. Thepreceding subject matter of this paragraph characterizes example 237 ofthe present disclosure, wherein example 237 also includes the subjectmatter according to any one of examples 234-236, above.

Removable gasket 105 may be used, for example, when surface 114 has avacuum applied thereto, to define an area within which composite part102 is being built on surface 114.

Referring, e.g., to FIG. 1 and particularly to FIG. 34, method 300further comprises (block 305) texturing continuous flexible line 106 ascontinuous flexible line 106 is being deposited. The preceding subjectmatter of this paragraph characterizes example 238 of the presentdisclosure, wherein example 238 also includes the subject matteraccording to any one of examples 188-237, above.

By texturing continuous flexible line 106 as it is being deposited,adhesion between adjacent layers of continuous flexible line may beachieved.

Referring, e.g., to FIGS. 1-5 and particularly to FIG. 35, method 400 ofadditively manufacturing composite part 102 is disclosed. Method 400comprises (block 402) applying thermosetting resin 252 to non-resincomponent 108 of continuous flexible line 106 while pushing non-resincomponent 108 through delivery guide 112 and pushing continuous flexibleline 106 out of delivery guide 112. Continuous flexible line 106 furthercomprises thermosetting resin component 110 that comprises at least someof thermosetting resin 252 applied to non-resin component 108. Method400 further comprises (block 404) depositing, via delivery guide 112,segment 120 of continuous flexible line 106 along print path 122. Thepreceding subject matter of this paragraph characterizes example 239 ofthe present disclosure.

Method 400 therefore may be performed to manufacture composite parts 102from at least a composite material that includes non-resin component 108and thermosetting resin component 110. By applying thermosetting resin252 to non-resin component 108 during the manufacture of composite part102, continuous flexible line 106 is created during manufacture ofcomposite part 102. Accordingly, different non-resin components 108and/or different thermosetting resins 252 may be selected duringperformance of method 400 to customize or otherwise create a desiredcomposite part 102 with different characteristics at different locationswithin composite part 102. Moreover, method 400 may be performed tomanufacture composite parts 102 with continuous flexible line 106 beingoriented in desired and/or predetermined orientations throughoutcomposite part 102, such as to define desired properties of compositepart 102.

Method 400 may be performed by system 100.

Referring, e.g., to FIGS. 1-5 and particularly to FIG. 35, according tomethod 400, (block 402) applying thermosetting resin 252 to non-resincomponent 108 comprises (block 406) injecting thermosetting resin 252into delivery guide 112. The preceding subject matter of this paragraphcharacterizes example 240 of the present disclosure, wherein example 240also includes the subject matter according to example 239, above.

Injecting thermosetting resin 252 into delivery guide 112, as opposedto, e.g., pulling non-resin component 108 through a resin bath, permitsfor precise control of the application of thermosetting resin 252 tonon-resin component 108.

Referring, e.g., to FIGS. 1-3 and 5 and particularly to FIG. 35,according to method 400, (block 406) injecting thermosetting resin 252into delivery guide 112 comprises (block 408) separately injecting firstpart 253 of thermosetting resin 252 and second part 255 of thermosettingresin 252 into delivery guide 112. The preceding subject matter of thisparagraph characterizes example 241 of the present disclosure, whereinexample 241 also includes the subject matter according to example 240,above.

By separately injecting first part 253 and second part 255 into deliveryguide 112, and thus, e.g., closer to outlet 206 of delivery guide 112,the amount of time that first part 253 and second part 255 areintermixed prior to being deposited as part of thermosetting resincomponent 110 may be minimized. As a result, curing of thermosettingresin component 110 and continuous flexible line 106 may be restricteduntil continuous flexible line 106 is deposited by delivery guide 112.

Referring, e.g., to FIGS. 1-3 and 5 and particularly to FIG. 35, method400 further comprises (block 410) mixing first part 253 and second part255 of thermosetting resin 252 within delivery guide 112. The precedingsubject matter of this paragraph characterizes example 242 of thepresent disclosure, wherein example 242 also includes the subject matteraccording to example 241, above.

By mixing first part 253 and second part 255 within delivery guide 112,the amount of time that first part 253 and second part 255 areintermixed prior to being deposited as part of thermosetting resincomponent 110 may be minimized. As a result, curing of thermosettingresin component 110 and continuous flexible line 106 may be restricteduntil continuous flexible line 106 is deposited by delivery guide 112.

Referring, e.g., to FIGS. 1 and 4 and particularly to FIG. 35, method400 further comprises (block 412) mixing first part 253 of thermosettingresin 252 and second part 255 of thermosetting resin 252 externally todelivery guide 112. The preceding subject matter of this paragraphcharacterizes example 243 of the present disclosure, wherein example 243also includes the subject matter according to example 240, above.

Mixing first part 253 and second part 255 externally to delivery guide112 may provide for a less complex delivery guide structure and moreefficient packaging of delivery guide 112. Moreover, as discussedherein, such a configuration may facilitate use of off-the-shelf resinmixers that may be easily and inexpensively replaced, when needed.

Referring, e.g., to FIGS. 1, 4, and 5 and particularly to FIG. 35,according to method 400, (block 402) applying thermosetting resin 252 tonon-resin component 108 comprises (block 414) metering a flow ofthermosetting resin 252. The preceding subject matter of this paragraphcharacterizes example 244 of the present disclosure, wherein example 244also includes the subject matter according to any one of examples239-243, above.

Metering the flow of thermosetting resin 252 permits for the selectiveincrease and the selective decrease of the volume of thermosetting resin252 applied to non-resin component 108. Accordingly, a desired level ofsaturation of non-resin component 108 with thermosetting resin 252 maybe achieved.

Referring, e.g., to FIGS. 1, 4, and 5 and particularly to FIG. 35,according to method 400, (block 414) metering the flow of thermosettingresin 252 comprises (block 416) detecting a level of thermosetting resin252 within delivery guide 112. The preceding subject matter of thisparagraph characterizes example 245 of the present disclosure, whereinexample 245 also includes the subject matter according to example 244,above.

Detection of a level of thermosetting resin 252 within delivery guide112 provides a data input for metering the flow of thermosetting resin252 to non-resin component 108.

Referring, e.g., to FIGS. 1, 4, and 5 and particularly to FIG. 35,according to method 400, (block 414) metering the flow of thermosettingresin 252 comprises (block 418) selectively reducing or selectivelyincreasing the flow of thermosetting resin 252 to delivery guide 112responsive to the level of thermosetting resin 252 within delivery guide112. The preceding subject matter of this paragraph characterizesexample 246 of the present disclosure, wherein example 246 also includesthe subject matter according to example 245, above.

The selective reduction of the flow of thermosetting resin 252 permitsfor avoidance of overflowing thermosetting resin 252 from delivery guide112. The selective increase of the flow of thermosetting resin 252permits for avoidance of an undesirably low level of saturation ofnon-resin component 108 with thermosetting resin 252.

Referring, e.g., to FIGS. 1, 4, and 5 and particularly to FIG. 35,according to method 400, (block 414) metering the flow of thermosettingresin 252 comprises (block 420) detecting a saturation level ofnon-resin component 108 with thermosetting resin 252. The precedingsubject matter of this paragraph characterizes example 247 of thepresent disclosure, wherein example 247 also includes the subject matteraccording to any one of examples 244-246, above.

Detecting a saturation level of non-resin component 108 withthermosetting resin 252, as opposed to, e.g., simply detecting thepresence of thermosetting resin 252 at a given position, may facilitateprecisely ensuring a desired level of saturation, such as ensuringadequate penetration of non-resin component 108 with thermosetting resin252.

Referring, e.g., to FIGS. 1, 4, and 5 and particularly to FIG. 35,according to method 400, (block 414) metering the flow of thermosettingresin 252 comprises (block 422) selectively reducing or selectivelyincreasing the flow of thermosetting resin 252 to delivery guide 112responsive to the saturation level of non-resin component 108 withthermosetting resin 252. The preceding subject matter of this paragraphcharacterizes example 248 of the present disclosure, wherein example 248also includes the subject matter according to example 247, above.

The selective reduction and the selective increase of the flow ofthermosetting resin 252 responsive to the saturation level facilitateprecisely achieving a desired level of saturation of non-resin component108 with thermosetting resin 252.

Referring, e.g., to FIGS. 1, 4, and 5 and particularly to FIG. 35,according to method 400, (block 414) metering the flow of thermosettingresin 252 comprises (block 424) metering a flow of first part 253 ofthermosetting resin 252 and metering a flow of second part 255 ofthermosetting resin 252. The preceding subject matter of this paragraphcharacterizes example 249 of the present disclosure, wherein example 249also includes the subject matter according to any one of examples244-248, above.

Metering the flow of first part 253 and second part 255, that is beforethey are mixed to create thermosetting resin 252, permits for separatelyincreasing and decreasing the flow of first part 253 and second part255. Accordingly, while composite part 102 is being manufactured, theratio of first part 253 to second part 255 may be actively varied, suchas to result in desired properties of continuous flexible line 106 alongits length and to result in varied properties at different locationswithin composite part 102.

Referring, e.g., to FIGS. 6 and 7 and particularly to FIG. 35, accordingto method 400, (block 426) non-resin component 108 comprises one or moreof a fiber, a carbon fiber, a glass fiber, a synthetic organic fiber, anaramid fiber, a natural fiber, a wood fiber, a boron fiber, asilicon-carbide fiber, an optical fiber, a fiber bundle, a fiber tow, afiber weave, a wire, a metal wire, a conductive wire, or a wire bundle.The preceding subject matter of this paragraph characterizes example 250of the present disclosure, wherein example 250 also includes the subjectmatter according to any one of examples 239-249, above.

Inclusion of a fiber or fibers in continuous flexible line 106 permitsfor selecting desired properties of composite part 102. Moreover,selection of specific materials of fibers and/or selection of specificconfigurations of fibers (e.g., a bundle, a tow, and/or a weave) maypermit for precise selection of desired properties of composite part102. Example properties of composite parts 102 include strength,stiffness, flexibility, ductility, hardness, electrical conductivity,thermal conductivity, etc. Non-resin component 108 is not limited to theidentified examples, and other types of non-resin component 108 may beused.

FIG. 6 schematically represents continuous flexible line 106 with asingle fiber as non-resin component 108 within a matrix of thermosettingresin component 110. FIG. 7 schematically represents continuous flexibleline 106 with more than one fiber as non-resin component 108 within amatrix of thermosetting resin component 110.

Referring, e.g., to FIGS. 1 and 8 and particularly to FIG. 35, accordingto method 400, (block 404) depositing segment 120 of continuous flexibleline 106 along print path 122 comprises (block 428) layering continuousflexible line 106 against itself to additively manufacture compositepart 102. The preceding subject matter of this paragraph characterizesexample 251 of the present disclosure, wherein example 251 also includesthe subject matter according to any one of examples 239-250, above.

By layering continuous flexible line 106 against itself or a previouslydeposited segment 120, a three-dimensional composite part 102 may bemanufactured by performance of method 400.

Referring, e.g., to FIG. 1 and particularly to FIG. 35, according tomethod 400, (block 404) depositing segment 120 of continuous flexibleline 106 along print path 122 comprises (block 430) depositingcontinuous flexible line 106 in a predetermined pattern to selectivelycontrol one or more physical characteristics of composite part 102. Thepreceding subject matter of this paragraph characterizes example 252 ofthe present disclosure, wherein example 252 also includes the subjectmatter according to any one of examples 239-251, above.

By controlling one or more physical characteristics of composite part102, less overall material may be used and/or the size of a specificpart may be reduced when compared to a similar part manufactured by atraditional composite layup method.

For example, in contrast to composite parts constructed from multiplelayers of planar plies of composite material, composite part 102 may bemanufactured so that the orientation of continuous flexible line 106,and thus of non-resin component 108, results in desired properties. Asan example, if a part includes holes, continuous flexible line 106 maybe arranged generally in concentric circles or spiral around the holes,resulting in no or few interruptions to continuous flexible line 106 atthe boundary of the holes. As a result, the strength of the compositepart may be significantly greater around the hole than a similar partconstructed by traditional composite layup methods. In addition thecomposite part may be less subject to cracks and propagation thereof atthe boundary of the holes. Moreover, because of the desired propertiesaround the holes, the overall thickness, volume, and/or mass of thecomposite part may be reduced while achieving the desired properties,when compared to a similar part constructed by traditional compositelayup methods.

Referring to FIG. 35, according to method 400, (block 432) the physicalcharacteristics include at least one of strength, stiffness,flexibility, ductility, or hardness. The preceding subject matter ofthis paragraph characterizes example 253 of the present disclosure,wherein example 253 also includes the subject matter according toexample 252, above.

Each of these physical characteristics may be selected for a particularpurpose. For example, in a composite part that when in use receives asignificant torque on a sub-part thereof compared to the remainder ofthe composite part, it may be desirable to have such sub-part less stiffand/or more flexible than other portions of the composite part.Additionally, it may be desirable to build more strength into a sub-partthan other portions of composite part 102 for various reasons dependingon a specific application of composite part 102.

Referring, e.g., to FIGS. 1, 8-11, 14, 21, and 23-28 and particularly toFIG. 35, method 400 further comprises (block 434) delivering apredetermined or actively determined amount of curing energy 118 atleast to portion 124 of segment 120 of continuous flexible line 106 at acontrolled rate while advancing continuous flexible line 106 towardprint path 122 and after segment 120 of continuous flexible line 106 isdeposited along print path 122 to at least partially cure at leastportion 124 of segment 120 of continuous flexible line 106. Thepreceding subject matter of this paragraph characterizes example 254 ofthe present disclosure, wherein example 254 also includes the subjectmatter according to any one of examples 239-253, above.

By delivering a predetermined or actively determined amount of curingenergy 118 to portion 124, continuous flexible line 106, and thuscomposite part 102, is at least partially cured while composite part 102is being manufactured, or in situ. As a result of delivering apredetermined or actively determined amount of curing energy 118 at acontrolled rate, a desired level, or degree, of cure may be establishedwith respect to portion 124 of segment 120 at any given time duringmanufacture of composite part 102. For example, as discussed herein, insome examples, it may be desirable to cure one portion 124 greater thanor less than another portion 124 during manufacture of composite part102.

Referring, e.g., to FIGS. 1 and 8 and particularly to FIG. 35, accordingto method 400, (block 434) delivering the predetermined or activelydetermined amount of curing energy 118 at least to portion 124 ofsegment 120 of continuous flexible line 106 at the controlled ratecomprises (block 436) partially curing first layer 140 of segment 120 ofcontinuous flexible line 106 as first layer 140 is being deposited andfurther curing first layer 140 as second layer 142 is being depositedagainst first layer 140. The preceding subject matter of this paragraphcharacterizes example 255 of the present disclosure, wherein example 255also includes the subject matter according to example 254, above.

By only partially curing first layer 140 as first layer 140 is beingdeposited, first layer 140 may remain tacky, or sticky, therebyfacilitating adhesion of second layer 142 against first layer 140 assecond layer 142 is deposited against first layer 140. Then, first layer140 is further cured as second layer 142 is being partially cured fordeposition of a subsequent layer against second layer 142, and so forth.

Referring, e.g., to FIGS. 1 and 8 and particularly to FIG. 35, accordingto method 400, (block 434) delivering the predetermined or activelydetermined amount of curing energy 118 at least to portion 124 ofsegment 120 of continuous flexible line 106 at the controlled ratecomprises (block 438) partially curing first layer 140 of segment 120 ofcontinuous flexible line 106 as first layer 140 is being deposited andfully curing first layer 140 as second layer 142 is being depositedagainst first layer 140. The preceding subject matter of this paragraphcharacterizes example 256 of the present disclosure, wherein example 256also includes the subject matter according to any one of examples 254 or255, above.

Again, by only partially curing first layer 140 as first layer 140 isbeing deposited, first layer 140 may remain tacky, or sticky, therebyfacilitating adhesion of second layer 142 against first layer 140 assecond layer 142 is deposited against first layer 140. However,according to this example 256, first layer 140 is fully cured as secondlayer 142 is being partially cured.

Referring, e.g., to FIG. 1 and particularly to FIG. 35, according tomethod 400, (block 434) delivering the predetermined or activelydetermined amount of curing energy 118 at least to portion 124 ofsegment 120 of continuous flexible line 106 at the controlled ratecomprises (block 440) curing less than an entirety of composite part102. The preceding subject matter of this paragraph characterizesexample 257 of the present disclosure, wherein example 257 also includesthe subject matter according to any one of examples 254-256, above.

In some applications, a less cured portion may be desirable so that itmay be subsequently worked on by a subsequent process, such as to removematerial and/or add a structural or other component to composite part102.

Referring, e.g., to FIG. 1 and particularly to FIG. 35, method 400further comprises (block 442) restrictively curing at least a portion ofcomposite part 102. The preceding subject matter of this paragraphcharacterizes example 258 of the present disclosure, wherein example 258also includes the subject matter according to any one of examples254-257, above.

Again, in some applications, a less cured portion may be desirable sothat it may be subsequently worked on by a subsequent process, such asto remove material and/or add a structural or other component tocomposite part 102, and a less cured portion may result from restrictionof the curing process.

Referring, e.g., to FIG. 1 and particularly to FIG. 35, according tomethod 400, (block 444) the portion of composite part 102 isrestrictively cured to facilitate subsequent processing of the portionof composite part 102. The preceding subject matter of this paragraphcharacterizes example 259 of the present disclosure, wherein example 259also includes the subject matter according to example 258, above.

Subsequent processing on composite part 102 may be desirable, such as toremove material and/or add a structural or other component to compositepart 102.

Referring, e.g., to FIG. 1 and particularly to FIG. 35, according tomethod 400, (block 434) delivering the predetermined or activelydetermined amount of curing energy 118 at least to portion 124 ofsegment 120 of continuous flexible line 106 at the controlled ratecomprises (block 446) selectively varying at least one of a deliveryrate, a delivery duration, or a temperature of curing energy 118 toimpart varying physical characteristics to composite part 102. Thepreceding subject matter of this paragraph characterizes example 260 ofthe present disclosure, wherein example 260 also includes the subjectmatter according to any one of examples 254-259, above.

By imparting varying physical characteristics of composite part 102, acustomized composite part 102 may be manufactured with sub-parts havingdesirable properties that are different from other sub-parts.

Referring to FIG. 35, according to method 400, (block 448) the varyingphysical characteristics include at least one of strength, stiffness,flexibility, ductility, or hardness. The preceding subject matter ofthis paragraph characterizes example 261 of the present disclosure,wherein example 261 also includes the subject matter according toexample 260, above.

Each of these physical characteristics may be selected for a particularpurpose. For example, in composite part 102 that when in use receives asignificant torque on a sub-part thereof compared to the remainder ofcomposite part 102, it may be desirable to have such sub-part less stiffand/or more flexible than other parts of composite part 102.Additionally, it may be desirable to build more strength into a sub-partthan other parts of composite part 102 for various reasons depending ona specific application of composite part 102.

Referring, e.g., to FIG. 1 and particularly to FIG. 35, method 400further comprises (block 450), simultaneously with delivering thepredetermined or actively determined amount of curing energy 118 atleast to portion 124 of segment 120 of continuous flexible line 106 atthe controlled rate, at least partially protecting at least portion 124of segment 120 of continuous flexible line 106 from oxidation aftersegment 120 exits delivery guide 112. The preceding subject matter ofthis paragraph characterizes example 262 of the present disclosure,wherein example 262 also includes the subject matter according to anyone of examples 254-261, above.

Protecting portion 124 from oxidation may facilitate the subsequentand/or simultaneous curing of portion 124.

Referring, e.g., to FIG. 1 and particularly to FIG. 35, according tomethod 400, (block 452) at least portion 124 of segment 120 ofcontinuous flexible line 106 is at least partially protected fromoxidation with shielding gas 221. The preceding subject matter of thisparagraph characterizes example 263 of the present disclosure, whereinexample 263 also includes the subject matter according to example 262,above.

Again, protecting portion 124 from oxidation may facilitate thesubsequent and/or simultaneous curing of portion 124.

Referring, e.g., to FIGS. 1, 12-16, 23, and 25 and particularly to FIG.35, method 400 further comprises (block 454), simultaneously withdepositing segment 120 of continuous flexible line 106 along print path122, compacting at least section 180 of segment 120 of continuousflexible line 106 after segment 120 of continuous flexible line 106 isdeposited along print path 122. The preceding subject matter of thisparagraph characterizes example 264 of the present disclosure, whereinexample 264 also includes the subject matter according to any one ofexamples 239-263, above.

Compaction of section 180 of continuous flexible line 106 duringperformance of method 400 facilitates adherence between adjacent layersof continuous flexible line 106 being deposited during performance ofmethod 400.

Referring, e.g., to FIG. 13 and particularly to FIG. 35, according tomethod 400, (block 454) compacting at least section 180 of segment 120of continuous flexible line 106 after segment 120 of continuous flexibleline 106 is deposited along print path 122 comprises (block 456)imparting a desired cross-sectional shape to segment 120 of continuousflexible line 106. The preceding subject matter of this paragraphcharacterizes example 265 of the present disclosure, wherein example 265also includes the subject matter according to example 264, above.

It may be desirable, in some applications, to impart a predeterminedcross-sectional shape to continuous flexible line 106 as it is beingdeposited.

Referring, e.g., to FIGS. 1, 12-16, 23, and 25 and particularly to FIG.35, according to method 400, (block 454) compacting at least section 180of segment 120 of continuous flexible line 106 after segment 120 ofcontinuous flexible line 106 is deposited along print path 122 comprises(block 480) heating section 180 of segment 120 of continuous flexibleline 106 to at least partially cure at least section 180 of segment 120of continuous flexible line 106. The preceding subject matter of thisparagraph characterizes example 266 of the present disclosure, whereinexample 266 also includes the subject matter according to any one ofexamples 264 or 265, above.

Having compaction also deliver heat to continuous flexible line 106efficiently cures continuous flexible line 106.

Referring, e.g., to FIGS. 1, 12, and 23 and particularly to FIG. 35,method 400 further comprises (block 458), simultaneously with depositingsegment 120 of continuous flexible line 106 along print path 122,roughening at least section 194 of segment 120 of continuous flexibleline 106 after segment 120 of continuous flexible line 106 is depositedalong print path 122. The preceding subject matter of this paragraphcharacterizes example 267 of the present disclosure, wherein example 267also includes the subject matter according to any one of examples239-266, above.

Roughening section 194 of continuous flexible line 106 increases thesurface area thereof and aids in adhesion of a subsequent layer ofcontinuous flexible line 106 deposited against it during performance ofmethod 400.

Referring, e.g., to FIGS. 1 and 23 and particularly to FIG. 35, method400 further comprises (block 460), simultaneously with roughening atleast section 194 of segment 120 of continuous flexible line 106,collecting debris resulting from roughening at least section 194 ofsegment 120 of continuous flexible line 106. The preceding subjectmatter of this paragraph characterizes example 268 of the presentdisclosure, wherein example 268 also includes the subject matteraccording to example 267, above.

Collection of debris that results from roughening section 194 avoidsunwanted, loose particles of thermosetting resin component 110 becomingtrapped between adjacent deposited layers of continuous flexible line106 that may otherwise result in unwanted properties of composite part102.

Referring, e.g., to FIGS. 1 and 23 and particularly to FIG. 35, method400 further comprises (block 462), simultaneously with roughening atleast section 194 of segment 120 of continuous flexible line 106,dispersing debris resulting from roughening at least section 194 ofsegment 120 of continuous flexible line 106. The preceding subjectmatter of this paragraph characterizes example 269 of the presentdisclosure, wherein example 269 also includes the subject matteraccording to any one of examples 267 or 268, above.

Dispersal of debris that results from roughening section 194 avoidsunwanted, loose particles of thermosetting resin component 110 becomingtrapped between adjacent deposited layers of continuous flexible line106 that may otherwise result in unwanted properties of composite part102.

Referring, e.g., to FIGS. 1 and 23 and particularly to FIG. 35,according to method 400, (block 458) roughening at least section 194 ofsegment 120 of continuous flexible line 106 after segment 120 ofcontinuous flexible line 106 is deposited along print path 122 comprises(block 482) heating section 194 of segment 120 of continuous flexibleline 106 to at least partially cure at least section 194 of segment 120of continuous flexible line 106. The preceding subject matter of thisparagraph characterizes example 270 of the present disclosure, whereinexample 270 also includes the subject matter according to any one ofexamples 267-269, above.

Having the roughening also deliver heat to continuous flexible line 106efficiently cures continuous flexible line 106.

Referring, e.g., to FIGS. 1, 17-20, 23, 32, and 33 and particularly toFIG. 35, method 400 further comprises (block 464) selectively cuttingcontinuous flexible line 106. The preceding subject matter of thisparagraph characterizes example 271 of the present disclosure, whereinexample 271 also includes the subject matter according to any one ofexamples 239-270, above.

Selective cutting of continuous flexible line 106 during performance ofmethod 300 permits for the stopping and starting of continuous flexibleline 106 in different locations on composite part 102.

Referring, e.g., to FIGS. 1, 17-20, 23, 32, and 33 and particularly toFIG. 35, according to method 400, (block 466) continuous flexible line106 is selectively cut simultaneously with depositing segment 120 ofcontinuous flexible line 106 along print path 122. The preceding subjectmatter of this paragraph characterizes example 272 of the presentdisclosure, wherein example 272 also includes the subject matteraccording to example 271, above.

Simultaneous cutting and delivering of continuous flexible line 106provides for controlled deposition of continuous flexible line 106 alongprint path 122.

Referring, e.g., to FIG. 1 and particularly to FIG. 35, method 400further comprises (block 468), simultaneously with depositing segment120 of continuous flexible line 106 along print path 122, detectingdefects in composite part 102. The preceding subject matter of thisparagraph characterizes example 273 of the present disclosure, whereinexample 273 also includes the subject matter according to any one ofexamples 239-272, above.

Detection of defects in segment 120 permits for selective scrapping ofcomposite parts 102 having defects prior to completion of compositeparts 102. Accordingly, less material may be wasted. Moreover, defectsthat otherwise would be hidden from view by various types of defectdetectors may be detected prior to a subsequent layer of continuousflexible line 106 obscuring, or hiding, the defect from view.

Referring, e.g., to FIG. 1 and particularly to FIG. 35, according tomethod 400, (block 404) depositing segment 120 of continuous flexibleline 106 along print path 122 comprises (block 470) depositing at leasta portion of segment 120 of continuous flexible line 106 over asacrificial layer. The preceding subject matter of this paragraphcharacterizes example 274 of the present disclosure, wherein example 274also includes the subject matter according to any one of examples239-273, above.

Use of a sacrificial layer may permit for deposition of an initial layerof continuous flexible line 106 in midair without requiring an outermold, surface 114, or other rigid structure for initial deposition ofthe initial layer. That is, the sacrificial layer may become an outermold for subsequent deposition of layers that are not sacrificial.Additionally or alternatively, the sacrificial layer may be depositedwithin an internal volume of composite part 102, such as to facilitatethe formation of a void within composite part 102, with the sacrificiallayer remaining within the void or with the sacrificial layersubsequently being removed or otherwise disintegrated, for example, sothat it does not impact the structural integrity of composite part 102.

Referring, e.g., to FIG. 1 and particularly to FIG. 35, method 400further comprises (block 472) removing the sacrificial layer to formcomposite part 102. The preceding subject matter of this paragraphcharacterizes example 275 of the present disclosure, wherein example 275also includes the subject matter according to example 274, above.

Removal of the sacrificial layer results in composite part 102 being ina desired state, which may be a completed state or may be a state thatis subsequently operated on by processes after completion of method 400.

Referring, e.g., to FIG. 1 and particularly to FIG. 35, method 400further comprises (block 474) depositing segment 120A of continuousflexible line 106A along print path 122. The preceding subject matter ofthis paragraph characterizes example 276 of the present disclosure,wherein example 276 also includes the subject matter according to anyone of examples 239-275, above.

In other words, different configurations of continuous flexible line 106may be used during performance of method 400.

For example, different properties of different continuous flexible lines106 may be selected for different sub-parts of composite part 102. As anexample, continuous flexible line 106 may comprise non-resin component108 that comprises carbon fiber for a significant portion of compositepart 102, but continuous flexible line 106 may comprise non-resincomponent 108 that comprises copper wiring for another portion to definean integral electrical path for connection to an electrical component.Additionally or alternatively, a different non-resin component 108 maybe selected for an outer surface of composite part 102 than non-resincomponent 108 selected for internal portions of composite part 102.Various other examples also are within the scope of example 276.

Referring to FIG. 35, according to method 400, (block 476) continuousflexible line 106A differs from continuous flexible line 106 in at leastone of non-resin component 108 or thermosetting resin component 110. Thepreceding subject matter of this paragraph characterizes example 277 ofthe present disclosure, wherein example 277 also includes the subjectmatter according to example 276, above.

Varying non-resin component 108 and/or thermosetting resin component 110during performance of method 400 permits for customized composite parts102 to be manufactured with varying and desired properties throughoutcomposite part 102.

Referring, e.g., to FIGS. 1, 4, 5, and 29-31 and particularly to FIG.35, method 400 further comprises (block 478) curing composite part 102in an autoclave or in an oven. The preceding subject matter of thisparagraph characterizes example 278 of the present disclosure, whereinexample 278 also includes the subject matter according to any one ofexamples 239-277, above.

By pushing continuous flexible line 106 through delivery guide 112,delivery guide 112 may be positioned downstream of the source of motiveforce that pushes continuous flexible line 106, such as feed mechanism104 herein. As a result, such source of motive force does not interferewith deposition of continuous flexible line 106, and delivery guide 112may be more easily manipulated in complex three-dimensional patternsduring performance of method 400.

Referring, e.g., to FIG. 1 and particularly to FIG. 35, method 400further comprises (block 484) maintaining thermosetting resin 252 belowa threshold temperature at least prior to applying thermosetting resin252 to non-resin component 108. The preceding subject matter of thisparagraph characterizes example 279 of the present disclosure, whereinexample 279 also includes the subject matter according to any one ofexamples 239-278, above.

Maintaining thermosetting resin 252 below a threshold temperature priorto being applied to non-resin component 108 restricts curing ofthermosetting resin component 110 before continuous flexible line 106 isdeposited.

Referring, e.g., to FIG. 1 and particularly to FIG. 35, method 400further comprises (block 486) maintaining thermosetting resin component110 below a threshold temperature prior to depositing segment 120 ofcontinuous flexible line 106 along print path 122. The preceding subjectmatter of this paragraph characterizes example 280 of the presentdisclosure, wherein example 280 also includes the subject matteraccording to any one of examples 239-279, above.

Maintaining thermosetting resin component 110 below a thresholdtemperature prior to continuous flexible line 106 being depositedrestricts curing of thermosetting resin component 110.

Referring to FIG. 35, according to method 400, (block 488) the thresholdtemperature is no greater than 20° C., 15° C., 10° C., 5° C., 0° C.,−50° C., −100° C., −150° C., −200° C., −200-−100° C., −100-0° C., −50-5°C., 5-20° C., 5-15° C., or 5-10° C. The preceding subject matter of thisparagraph characterizes example 281 of the present disclosure, whereinexample 281 also includes the subject matter according to any one ofexamples 279 or 280, above.

The threshold temperature associated with method 400 may be selectedbased on thermosetting resin 252 being used, and the examples set forthin example 202 are illustrative and non-exclusive.

Referring, e.g., to FIG. 1 and particularly to FIG. 35, according tomethod 400, (block 490) depositing segment 120 of continuous flexibleline 106 along print path 122 is performed within chamber 258 that isone of positively pressurized or negatively pressurized relative toatmospheric pressure. The preceding subject matter of this paragraphcharacterizes example 282 of the present disclosure, wherein example 282also includes the subject matter according to any one of examples239-281, above.

Depending on the configuration of composite part 102 being manufactured,it may be desirable to increase and/or decrease the pressure withinchamber 258 during curing to obtain desirable properties of compositepart 102.

Chamber 258 may be described as, or as comprising or as being comprisedby, an autoclave.

Referring, e.g., to FIG. 1 and particularly to FIG. 35, according tomethod 400, (block 404) depositing segment 120 of continuous flexibleline 106 along print path 122 comprises (block 492) initially depositingsegment 120 of continuous flexible line 106 against surface 114. Thepreceding subject matter of this paragraph characterizes example 283 ofthe present disclosure, wherein example 283 also includes the subjectmatter according to any one of examples 239-282, above.

Surface 114 therefore provides at least an initial deposition surface,against which continuous flexible line 106 may be deposited. However,subsequent layers of continuous flexible line 106 may be depositedagainst previously deposited layers of continuous flexible line 106,with surface 114 ultimately providing the structural support forcomposite part 102 and optionally compaction thereof.

Referring, e.g., to FIG. 1 and particularly to FIG. 35, method 400further comprises (block 494) heating surface 114. The preceding subjectmatter of this paragraph characterizes example 284 of the presentdisclosure, wherein example 284 also includes the subject matteraccording to example 283, above.

Selective heating of surface 114 may facilitate curing of an initiallayer of continuous flexible line 106 being deposited. Additionally oralternatively, selective heating of surface 114, such as at or near thecompletion of composite part 102, may facilitate removal of compositepart 102 from surface 114.

Referring, e.g., to FIG. 1 and particularly to FIG. 35, method 400further comprises (block 496) applying a vacuum to surface 114. Thepreceding subject matter of this paragraph characterizes example 285 ofthe present disclosure, wherein example 285 also includes the subjectmatter according to any one of examples 283 or 284, above.

Applying a vacuum to surface 114 secures composite part 102 to surface114 while composite part 102 is being manufactured by method 400.

Referring, e.g., to FIG. 1 and particularly to FIG. 35, according tomethod 400, (block 498) surface 114 comprises removable gasket 105. Thepreceding subject matter of this paragraph characterizes example 286 ofthe present disclosure, wherein example 286 also includes the subjectmatter according to any one of examples 283-285, above.

Removable gasket 105 may be used, for example, when surface 114 has avacuum applied thereto, to define an area within which composite part102 is being built on surface 114.

Referring, e.g., to FIG. 1 and particularly to FIG. 35, method 400further comprises (block 499) texturing continuous flexible line 106 ascontinuous flexible line 106 is being deposited. The preceding subjectmatter of this paragraph characterizes example 287 of the presentdisclosure, wherein example 287 also includes the subject matteraccording to any one of examples 239-286, above.

By texturing continuous flexible line 106 as it is being deposited,adhesion between adjacent layers of continuous flexible line 106 may beachieved.

Examples of the present disclosure may be described in the context ofaircraft manufacturing and service method 1100 as shown in FIG. 36 andaircraft 1102 as shown in FIG. 37. During pre-production, illustrativemethod 1100 may include specification and design (block 1104) ofaircraft 1102 and material procurement (block 1106). During production,component and subassembly manufacturing (block 1108) and systemintegration (block 1110) of aircraft 1102 may take place. Thereafter,aircraft 1102 may go through certification and delivery (block 1112) tobe placed in service (block 1114). While in service, aircraft 1102 maybe scheduled for routine maintenance and service (block 1116). Routinemaintenance and service may include modification, reconfiguration,refurbishment, etc. of one or more systems of aircraft 1102.

Each of the processes of illustrative method 1100 may be performed orcarried out by a system integrator, a third party, and/or an operatore.g., a customer. For the purposes of this description, a systemintegrator may include, without limitation, any number of aircraftmanufacturers and major-system subcontractors; a third party mayinclude, without limitation, any number of vendors, subcontractors, andsuppliers; and an operator may be an airline, leasing company, militaryentity, service organization, and so on.

As shown in FIG. 37, aircraft 1102 produced by illustrative method 1100may include airframe 1118 with a plurality of high-level systems 1120and interior 1122. Examples of high-level systems 1120 include one ormore of propulsion system 1124, electrical system 1126, hydraulic system1128, and environmental system 1130. Any number of other systems may beincluded. Although an aerospace example is shown, the principlesdisclosed herein may be applied to other industries, such as theautomotive industry. Accordingly, in addition to aircraft 1102, theprinciples disclosed herein may apply to other vehicles, e.g., landvehicles, marine vehicles, space vehicles, etc.

Apparatus(es) and method(s) shown or described herein may be employedduring any one or more of the stages of the manufacturing and servicemethod 1100. For example, components or subassemblies corresponding tocomponent and subassembly manufacturing (block 1108) may be fabricatedor manufactured in a manner similar to components or subassembliesproduced while aircraft 1102 is in service (block 1114). Also, one ormore examples of the apparatus(es), method(s), or combination thereofmay be utilized during production stages 1108 and 1110, for example, bysubstantially expediting assembly of or reducing the cost of aircraft1102. Similarly, one or more examples of the apparatus or methodrealizations, or a combination thereof, may be utilized, for example andwithout limitation, while aircraft 1102 is in service (block 1114)and/or during maintenance and service (block 1116).

Different examples of the apparatus(es) and method(s) disclosed hereininclude a variety of components, features, and functionalities. Itshould be understood that the various examples of the apparatus(es) andmethod(s) disclosed herein may include any of the components, features,and functionalities of any of the other examples of the apparatus(es)and method(s) disclosed herein in any combination, and all of suchpossibilities are intended to be within the scope of the presentdisclosure.

Many modifications of examples set forth herein will come to mind to oneskilled in the art to which the present disclosure pertains having thebenefit of the teachings presented in the foregoing descriptions and theassociated drawings.

Therefore, it is to be understood that the present disclosure is not tobe limited to the specific examples illustrated and that modificationsand other examples are intended to be included within the scope of theappended claims. Moreover, although the foregoing description and theassociated drawings describe examples of the present disclosure in thecontext of certain illustrative combinations of elements and/orfunctions, it should be appreciated that different combinations ofelements and/or functions may be provided by alternative implementationswithout departing from the scope of the appended claims. Accordingly,parenthetical reference numerals in the appended claims are presentedfor illustrative purposes only and are not intended to limit the scopeof the claimed subject matter to the specific examples provided in thepresent disclosure.

1-187. (canceled)
 188. A method (300) of additively manufacturing acomposite part (102), the method (300) comprising: depositing a segment(120) of a continuous flexible line (106) along a print path (122),wherein the continuous flexible line (106) comprises a non-resincomponent (108) and a thermosetting resin component (110) that is notfully cured; and while advancing the continuous flexible line (106)toward the print path (122), delivering a predetermined or activelydetermined amount of curing energy (118) at least to a portion (124) ofthe segment (120) of the continuous flexible line (106) at a controlledrate after the segment (120) of the continuous flexible line (106) isdeposited along the print path (122) to at least partially cure at leastthe portion (124) of the segment (120) of the continuous flexible line(106).
 189. The method (300) according to claim 188, further comprisingapplying a thermosetting resin (252) to the non-resin component (108)while pushing the continuous flexible line (106) out of a delivery guide(112), wherein the thermosetting resin component (110) comprises atleast some of the thermosetting resin (252) applied to the non-resincomponent (108).
 190. The method (300) according to claim 189, whereinapplying the thermosetting resin (252) to the non-resin component (108)while pushing the continuous flexible line (106) out of the deliveryguide (112) comprises injecting the thermosetting resin (252) into thedelivery guide (112).
 191. The method (300) according to claim 190,wherein injecting the thermosetting resin (252) into the delivery guide(112) comprises separately injecting a first part (253) of thethermosetting resin (252) and a second part (255) of the thermosettingresin (252) into the delivery guide (112).
 192. The method (300)according to claim 191, further comprising mixing the first part (253)of the thermosetting resin (252) and the second part (255) of thethermosetting resin (252) within the delivery guide (112).
 193. Themethod (300) according to claim 190, further comprising mixing a firstpart (253) of the thermosetting resin (252) and a second part (255) ofthe thermosetting resin (252) externally to the delivery guide (112).194. (canceled)
 195. The method (300) according to claim 189, wherein:applying the thermosetting resin (252) to the non-resin component (108)while pushing the continuous flexible line (106) out of the deliveryguide (112) comprises metering a flow of the thermosetting resin (252);and metering the flow of the thermosetting resin (252) comprisesdetecting a level of the thermosetting resin (252) within the deliveryguide (112).
 196. (canceled)
 197. The method (300) according to claim189, wherein: applying the thermosetting resin (252) to the non-resincomponent (108) while pushing the continuous flexible line (106) out ofthe delivery guide (112) comprises metering a flow of the thermosettingresin (252); metering the flow of the thermosetting resin (252)comprises detecting a saturation level of the non-resin component (108)with the thermosetting resin (252); and metering the flow of thethermosetting resin (252) comprises selectively reducing or selectivelyincreasing the flow of the thermosetting resin (252) to the deliveryguide (112) responsive to the saturation level of the non-resincomponent (108) with the thermosetting resin (252). 198-199. (canceled)200. The method (300) according to claim 189, further comprising:maintaining the thermosetting resin (252) below a threshold temperatureat least prior to applying the thermosetting resin (252) to thenon-resin component (108). 201-207. (canceled)
 208. The method (300)according to claim 188, wherein delivering the predetermined or activelydetermined amount of the curing energy (118) at least to the portion(124) of the segment (120) of the continuous flexible line (106) at thecontrolled rate comprises partially curing a first layer (140) of thesegment (120) of the continuous flexible line (106) as the first layer(140) is being deposited and further curing the first layer (140) as asecond layer (142) is being deposited against the first layer (140).209-214. (canceled)
 215. The method (300) according to claim 188,further comprising, simultaneously with depositing the segment (120) ofthe continuous flexible line (106) along the print path (122),compacting at least a section (180) of the segment (120) of thecontinuous flexible line (106) after the segment (120) of the continuousflexible line (106) is deposited along the print path (122). 216.(canceled)
 217. The method (300) according to claim 215, whereincompacting at least the section (180) of the segment (120) of thecontinuous flexible line (106) after the segment (120) of the continuousflexible line (106) is deposited along the print path (122) comprisesheating the section (180) of the segment (120) of the continuousflexible line (106) to at least partially cure at least the section(180) of the segment (120) of the continuous flexible line (106). 218.The method (300) according to claim 188, further comprising,simultaneously with depositing the segment (120) of the continuousflexible line (106) along the print path (122), roughening at least asection (194) of the segment (120) of the continuous flexible line (106)after the segment (120) of the continuous flexible line (106) isdeposited along the print path (122). 219-220. (canceled)
 221. Themethod (300) according to claim 218, wherein roughening at least thesection (194) of the segment (120) of the continuous flexible line (106)after the segment (120) of the continuous flexible line (106) isdeposited along the print path (122) comprises heating the section (194)of the segment (120) of the continuous flexible line (106) to at leastpartially cure at least the section (194) of the segment (120) of thecontinuous flexible line (106).
 222. The method (300) according to claim188, further comprising selectively cutting the continuous flexible line(106), wherein the continuous flexible line (106) is selectively cutsimultaneously with depositing the segment (120) of the continuousflexible line (106) along the print path (122). 223-230. (canceled) 231.The method (300) according to claim 188, wherein depositing the segment(120) of the continuous flexible line (106) along the print path (122)comprises pushing the continuous flexible line (106) through a deliveryguide (112).
 232. (canceled)
 233. The method (300) according to claim188, wherein depositing the segment (120) of the continuous flexibleline (106) along the print path (122) and delivering the predeterminedor actively determined amount of curing energy (118) at least to theportion (124) of the segment (120) of the continuous flexible line (106)at the controlled rate are performed within a chamber (258) that is oneof positively pressurized or negatively pressurized relative toatmospheric pressure.
 234. (canceled)
 235. The method (300) according toclaim 188, wherein: depositing the segment (120) of the continuousflexible line (106) along the print path (122) comprises initiallydepositing the segment (120) of the continuous flexible line (106)against a surface (114); and the method (300) further comprises heatingthe surface (114).
 236. The method (300) according to claim 188,wherein: depositing the segment (120) of the continuous flexible line(106) along the print path (122) comprises initially depositing thesegment (120) of the continuous flexible line (106) against a surface(114); and the method (300) further comprises applying a vacuum to thesurface (114).
 237. (canceled)
 238. The method (300) according to claim188, further comprising texturing the continuous flexible line (106) asthe continuous flexible line (106) is being deposited. 239-287.(canceled)